Halogen substituted heterocyclic heteroatom containing ligands-alumoxane activation of metallocenes

ABSTRACT

This invention relates to an activator, catalyst system, and the use thereof. In one aspect, the catalyst system includes one or more polymerization catalysts and at least one activator. The activator comprises one or more heterocyclic heteroatom containing ligands coordinated to an alumoxane, wherein the activator is a reaction product of one or more alumoxanes and one or more heterocyclic heteroatom containing compounds, the one or more heterocyclic heteroatom containing ligands represented by the formula: 
     
       
         
         
             
             
         
       
         
         
           
             where 
             Y is O, S, PH or NH; 
             wherein each substituent X2, X3, X4, X5, X6, and X7 is independently selected from the group consisting of hydrogen, chlorine, fluorine, iodine, and bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH; and 
             wherein the ratio of the heterocyclic heteroatom containing ligand to aluminum is between about 0.01 and about 10 molar equivalents. The catalyst system may be supported or non-supported.

FIELD OF THE INVENTION

The present invention relates to polymerization catalyst activator compounds, to methods of making these activator compounds, to polymerization catalyst systems containing these activator compounds, and to polymerization processes utilizing the same. More specifically, the activators of the invention are the reaction product of a halogen substituted indole and an alkyl alumoxane.

BACKGROUND OF THE INVENTION

Polymerization catalyst compounds are typically combined with an activator (or co-catalyst) to yield compositions having a vacant coordination site that will coordinate, insert, and polymerize olefins. Metallocene polymerization catalysts, for example, are typically activated with alumoxanes which are generally oligomeric compounds containing —Al(R)—O— subunits, where R is an alkyl group. A common alumoxane activator is methylalumoxane (MAO), typically produced by the hydrolysis of trimethylaluminum (TMA). MAO, however, is expensive to utilize because it generally must be added in great excess relative to the metallocene and because of the high cost of TMA. Additionally, MAO tends to be unstable as it precipitates out of solution over time.

As a result, alternative activators for metallocenes and other single-site polymerization catalysts have been discovered in recent years. For example, perfluorophenyl aluminum and borane complexes containing one anionic nitrogen-containing group have recently gained much attention.

Activator complexes having a Group 13 atom have also been suggested as a viable alternative to the expensive alumoxane activators. For example, U.S. Pat. Nos. 6,147,173 and 6,211,105 disclose a polymerization process and polymerization catalyst where the catalyst includes an activator complex having a Group 13 element and at least one halogenated, nitrogen-containing aromatic group ligand.

Each of these alternatives, including the formation of aluminoxane, requires multi-step, complicated syntheses. There is a need, therefore, to provide a simpler method of cocatalyst synthesis and catalyst activation. There is also a need to improve catalyst economics by providing a highly active co-catalyst.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the invention include an activator and a catalyst system comprising one or more polymerization catalysts and at least one activator. In one aspect, the activator includes heteroatom containing ligands coordinated to an alkyl alumoxane, wherein the activator is a reaction product of one or more alkyl alumoxanes and one or more heterocyclic heteroatom containing compounds, wherein the heterocyclic heteroatom containing ligands are represented by Formula (I):

wherein Y is O, S, PH or, in particular, NH;

wherein each substituent X2, X3, X4, X5, X6 and X7 is independently a hydrogen, chlorine, fluorine, iodine or bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH; and

wherein the ratio of the heterocyclic heteroatom containing ligand to aluminum is between about 0.01 and about 10:1 molar equivalents, more particularly between about 0.1 to about 5:1, even more particularly between about 0.2 to about 5:1, e.g. 0.3 to about 4:1 molar equivalents.

Surprisingly, altering of the ratio of heteroatom containing ligand to aluminum provides the ability to control the molecular weight of the polymer produced from a polymerization reaction.

The catalyst system may be supported or, preferably, non-supported.

In one aspect, the alumoxane is isobutylalumoxane.

In another aspect, the heterocyclic heteroatom containing ligand is a mono-substituted indole or a di-substituted indole. The substituents are halogens and in particular can be bromine or chlorine. In one aspect, the indole is mono-substituted or di-substituted with bromine and in particular is 5-bromoindole or 5-chloroindole. In another aspect, the halogen is not fluorine.

In yet another aspect, the catalyst system provides a method to prepare isotactic low molecular weight polymers, such as isotactic polypropylene with molecular weights, for example, between about 10,000 and about 200,000 g/mol. Unless otherwise stated all molecular weights are weight average molecular weights in units of g/mol.

In one particular aspect, the catalyst system includes 5-bromoindole in combination with a metallocene, such as rac-Me₂Si-(2-methyl-indenyl)₂Zr(CH₃)₂, rac-Me₂Si-(2-methyl-4-3′, 5′ di tert-butyl phenyl-indenyl)₂Zr(CH₃)₂ or rac-Me₂Si-(2-methyl-4-phenyl-indenyl)₂Zr(CH₃)₂, and isobutylalumoxane. Polymerization of propylene with this system provides an isotactic polypropylene having a molecular weight range of between about 10,000 and about 200,000, more particularly between about 15,000 and about 150,000 and more particularly between about 20,000 and about 100,000.

DETAILED DESCRIPTION

A catalyst system for olefin polymerization is provided. The catalyst system may be supported or non-supported and includes one or more catalysts and at least one activator. The activator is a reaction product of one or more alkyl alumoxanes and one or more heterocyclic heteroatom containing compounds having the general formula (I):

wherein Y is O, S, PH or NH;

wherein each substituent X2, X3, X4, X5, X6 and X7 is independently a hydrogen, chlorine, fluorine, iodine or bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH.

Preferably, the ring of the heterocyclic compound includes at least one nitrogen, oxygen, and/or sulfur atom, and more preferably includes at least one nitrogen atom. A non-limiting example of a heterocyclic compound includes indole. In a specific embodiment, the activator includes a mono-halogen substituted indole or a bi-halogen substituted indole. The halogen may be chlorine, iodine, bromine, fluorine, or any combination thereof. Preferably, the halogen is chlorine, bromine, fluorine, or any combination thereof.

The alkyl alumoxane is preferably a C to C12 alumoxane, such as methyl alumoxane, ethyl alumoxane, tri-isobutyl alumoxane or modified alumoxane. A preferred alumoxane is modified methyl alumoxane (MMAO) cocatalyst type 3A (commercially available from Akzo Chemicals, Inc. under the trade name Modified Methylalumoxane type 3A, covered under patent number U.S. Pat. No. 5,041,584. It may be preferable to use a visually clear methylalumoxane. A cloudy or gelled alumoxane can be filtered to produce a clear solution or clear alumoxane can be decanted from the cloudy solution.

The term “activator” as used herein refers to any compound or component, or combination of compounds or components, capable of enhancing the ability of a catalyst to polymerize olefin monomers to form polyolefins. The term “catalyst” is used interchangeably with the terms “catalyst component” and “catalyst compound”, and includes any compound or component, or combination of compounds or components, that is capable of increasing the rate of a chemical reaction, such as the polymerization or oligomerization of one or more olefins. The term “catalyst system” as used herein includes at least one “catalyst” and at least one “activator”.

The “catalyst system” may also include other components, such as a support for example. The catalyst system may include any number of catalysts in any combination as described herein, as well as any activator in any combination as described herein.

As used herein, in reference to Periodic Table “Groups” of Elements, the “new” numbering scheme for the Periodic Table Groups as used as in the CRC HANDBOOK OF CHEMISTRY AND PHYSICS (David R. Lide ed., CRC Press 81^(st) ed. 2000).

In a preferred embodiment, the activator includes one or more heterocyclic nitrogen-containing ligands coordinated to an alumoxane. The heterocyclic nitrogen-containing ligand is an indole represented by Formula (II).

The indole includes substituents X2, X3, X4, X5, X6, and X7 located about the heterocyclic ring, as shown in Formula (II). Each substituent X2 to X7 is independently selected from hydrogen, halogens, alkyl groups, aryl groups, alkoxide groups, aryloxide groups, cyano groups, nitrous groups, sulfonyl groups, nitrile groups, phosophyl groups, and alkyl substituted aryl groups wherein each group may be halogenated or partially halogenated.

In preferred embodiments, (in either formula I or II), X4 is a halogen and X2, X3, X5 X7 are each hydrogen. In another aspect, X5 is a halogen and X2×4, X6, and X7 are each hydrogen. In yet another aspect, X6 is a halogen and X2, X5 and X7 are each hydrogen. In still yet another aspect, both X5 and X6 are a halogen. The halogen may be chlorine, iodine, bromine, fluorine, or any combination thereof. Preferably, the halogen is chlorine, bromine, fluorine, or any combination thereof.

Preferred alumoxanes are oligomeric compounds containing —Al(R)—O— or —Al(R)₂—O— subunits, where R is an alkyl group, typically a C1 to C12 alkyl group. Examples of useful alumoxanes include methylalumoxane (MAO), modified methylalumoxane (MMAO), ethylalumoxane, triethylalumoxane, triisobutylalumoxane, tetraethyldialumoxane and di-isobutylalumoxane. There are a variety of methods for preparing alumoxane and modified alumoxanes, such as the methods described in U.S. Pat. No. 4,542,199 and Chen and Marks, 100 Chem. Rev. 1391 (2000).

Preferably, the alumoxane and the halogen substituted heterocyclic compounds of Formula (I) yield an activator represented by the following Formulas (IV) or (V):

[((JY)_(y)R′_(x))₂M—O—M((R′_(x)(JY)_(y))₂]_(m)  (IV)

or

(OMR′_(k)(JY)_(q))_(z)  (V)

M is aluminum;

(JY) represents the heterocyclic group of Formula (I) or Formula (II) and is associated with M, and preferably coordinated to M;

z is a number from 1 to 1000 preferably 1 to 100, more preferably 5 to 50, and even more preferably 5 to 25;

m is a number from 1 to 10, preferably 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10;

x is 0, 1, 2 3 or 4;

y is 1, 2, 3, or 4;

k is 0, 1, 2 3 or 4;

q is 1, 2, 3, or 4;

provided that x+y=the valence of M−1 and k+q=valence of M−2, where the valence of M is preferably 2, 3, 4, or 5; and

each R′ is, independently, a substituent group bonded to M. Non-limiting examples of substituent R′ groups include hydrogen, linear or branched alkyl radicals, linear or branched alkenyl radicals, linear or branched alkynyl radicals, cycloalkyl radicals, aryl radicals, acyl radicals, aroyl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbamoyl radicals, alkyl radicals, dialkyl radicals, carbamoyl radicals, acyloxy radicals, acylamino radicals, arylamino radicals, straight alkylene radicals, branched alkylene radicals, cyclic alkylene radicals, or any combination thereof.

More specific embodiments of R′ include a methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl group, including all their isomers, for example tertiary butyl, isopropyl, and the like. Other embodiments of R′ include hydrocarbyl radicals such as fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl, chlorobenzyl; hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl and the like; halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)silyl, methyl-bis(difluoromethyl)silyl, bromoethyldimethylgermyl and the like; disubstituted boron radicals including dimethylboron for example; disubstituted Group 15 radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine; and Group 16 radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulfide and ethylsulfide.

Further, each R′ may include carbon, silicon, boron, aluminum, nitrogen, phosphorous, oxygen, tin, sulfur, or germanium atoms and the like. Still further, each R′ may include olefins such as olefinically unsaturated substituents including vinyl-terminated ligands, such as but-3-enyl, prop-2-enyl, hex-5-enyl and the like, for example. Also, at least two R′ groups, preferably two adjacent R′ groups, may be joined to form a ring structure having from 3 to 30 atoms selected from carbon, nitrogen, oxygen, phosphorous, silicon, germanium, aluminum, boron, or a combination thereof. Also, a substituent group R′ such as 1-butanyl may form a carbon sigma bond to the metal M.

The ratio of the heterocyclic heteroatom containing ligand to aluminum is preferably between about 0.01 and about 10:1 molar equivalents, more particularly between about 0.1 to about 5:1, even more particularly between about 0.2 to about 5:1, e.g. 0.3 to about 4:1 molar equivalents.

Catalyst Compositions

The activators described above may be utilized in conjunction with any suitable polymerization catalyst to form an active polymerization catalyst system. Typically, the mole ratio of the metal of the activator to the metal of the catalyst composition is in the range of between 0.3:1 to 10,000:1, preferably 100:1 to 5000:1, and most preferably 500:1 to 2000:1. Exemplary polymerization catalysts include metallocene catalyst compositions, Group 15-containing metal catalyst compositions, and phenoxide transition metal catalyst compositions, which are discussed in more detail below.

Metallocene Catalyst Compositions

Metallocene catalyst compounds are generally described throughout in, for example, 1 & 2 METALLOCENE-BASED POLYOLEFINS (John Scheirs & W. Kaminsky eds., John Wiley & Sons, Ltd. 2000); G. G. Hlatky in 181 COORDINATION CHEM. REV. 243 296 (1999) and in particular, for use in the synthesis of polyethylene in 1 METALLOCENE-BASED POLYOLEFINS 261 377 (2000). The metallocene catalyst compounds as described herein include “half sandwich” and “full sandwich” compounds having one or more Cp ligands (cyclopentadienyl and ligands isolobal to cyclopentadienyl) bound to at least one Group 3 to Group 12 metal atom (preferably a group 4 atom, preferably Hf, Ti or Zr), and one or more leaving group(s) bound to the at least one metal atom. Hereinafter, these compounds will be referred to as “metallocenes” or “metallocene catalyst components”. The metallocene catalyst component may supported on a support material, and may be supported with or without another catalyst component.

The Cp ligands are one or more rings or ring system(s), at least a portion of which includes π-bonded systems, such as cycloalkadienyl ligands and heterocyclic analogues. The ring(s) or ring system(s) typically comprise atoms selected from the group consisting of Groups 13 to 16 atoms, and more particularly, the atoms that make up the Cp ligands are selected from the group consisting of carbon, nitrogen, oxygen, silicon, sulfur, phosphorous, germanium, boron and aluminum and combinations thereof, wherein carbon makes up at least 50% of the ring members. Even more particularly, the Cp ligand(s) are selected from the group consisting of substituted and unsubstituted cyclopentadienyl ligands and ligands isolobal to cyclopentadienyl, non-limiting examples of which include cyclopentadienyl, indenyl, fluorenyl and other structures. Further non-limiting examples of such ligands include cyclopentadienyl, cyclopentaphenanthreneyl, indenyl, benzindenyl, fluorenyl, octahydrofluorenyl, cyclooctatetraenyl, cyclopentacyclododecene, phenanthrindenyl, 3,4-benzofluorenyl, 9-phenylfluorenyl, 8-H-cyclopent[a]acenaphthylenyl, 7H-dibenzofluorenyl, indeno[1,2-9]anthrene, thiophenoindenyl, thiophenofluorenyl, hydrogenated versions thereof (e.g., 4,5,6,7-tetrahydroindenyl, or “H₄Ind”), substituted versions thereof (as described in more detail below), and heterocyclic versions thereof. Preferred Cp ligands include substituted and unsubstituted cyclopentadienyl, indenyl and fluorenyl groups. (by substituted is meant that at least one hydrogen on the cyclopentadienyl, indenyl or fluorenyl group is replaced with a non-hydrogen atom containing group, preferably a hydrocarbyl group (such as methyl, ethyl, propyl, butyl, isobutyl, hexyl, octyl, and the like) or a heteroatom containing group (preferred heteroatoms include N, P, Br, Cl, and the like).

The metal atom “M” of the metallocene catalyst compound, as described throughout the specification and claims, may be selected from the group consisting of Groups 3 through 12 atoms and lanthanide Group atoms in one embodiment; and selected from the group consisting of Groups 3 through 10 atoms in a more particular embodiment, and selected from the group consisting of Sc, Ti, Zr, Hf, V, Nb, Ta, Mn, Re, Fe, Ru, Os, Co, Rh, Ir, and Ni in yet a more particular embodiment; and selected from the group consisting of Groups 4, 5 and 6 atoms in yet a more particular embodiment, and a Ti, Zr, Hf atoms in yet a more particular embodiment, and Zr in yet a more particular embodiment. The oxidation state of the metal atom “M” may range from 0 to +7 in one embodiment; and in a more particular embodiment, is +1, +2, +3, +4 or +5; and in yet a more particular embodiment is +2, +3 or +4. The groups bound to the metal atom “M” are such that the compounds described below in the formulas and structures are neutral, unless otherwise indicated. The Cp ligand(s) form at least one chemical bond with the metal atom M to form the “metallocene catalyst compound”. The Cp ligands are distinct from the leaving groups bound to the catalyst compound in that they are not highly susceptible to substitution/abstraction reactions.

In one aspect, the one or more metallocene catalyst components are represented formula (VI):

C_(p) ^(A)C_(p) ^(B)MX_(n)

wherein M is as described above; each X is chemically bonded to M; each Cp group is chemically bonded to M; and n is 0 or an integer from 1 to 4, and either 1 or 2 in a particular embodiment.

The ligands represented by Cp^(A) and Cp^(B) in formula (VI) may be the same or different cyclopentadienyl ligands or ligands isolobal to cyclopentadienyl, either or both of which may contain heteroatoms and either or both of which may be substituted by a group R. In one embodiment, Cp.^(A) and Cp^(B) are independently selected from the group consisting of cyclopentadienyl, indenyl, tetrahydroindenyl, fluorenyl, and substituted derivatives of each.

Independently, each Cp^(A) and Cp^(B) of formula (VI) may be unsubstituted or substituted with any one or combination of substituent groups R. Non-limiting examples of substituent groups R as used in structure (VI) include hydrogen radicals, alkyls, alkenyls, alkynyls, cycloalkyls, aryls, acyls, aroyls, alkoxys, aryloxys, alkylthiols, dialkylamines, alkylamidos, alkoxycarbonyls, aryloxycarbonyls, carbamoyls, alkyl- and dialkyl-carbamoyls, acyloxys, acylaminos, arylaminos, and combinations thereof.

More particular non-limiting examples of alkyl substituents R associated with formula (VI) through (V) include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl, phenyl, methylphenyl, and tert-butylphenyl groups and the like, including all their isomers, for example tertiary-butyl, isopropyl, and the like. Other possible radicals include substituted alkyls and aryls such as, for example, fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl, chlorobenzyl and hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl and the like; and halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)silyl, methylbis(difluoromethyl)silyl, bromomethyldimethylgermyl and the like; and disubstituted boron radicals including dimethylboron for example; and disubstituted Group 15 radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine, Group 16 radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulfide and ethylsulfide. Other substituents R include olefins such as but not limited to olefinically unsaturated substituents including vinyl-terminated ligands, for example 3-butenyl, 2-propenyl, 5-hexenyl and the like. In one embodiment, at least two R groups, two adjacent R groups in one embodiment, are joined to form a ring structure having from 3 to 30 atoms selected from the group consisting of carbon, nitrogen, oxygen, phosphorous, silicon, germanium, aluminum, boron and combinations thereof. Also, a substituent group R group such as 1-butanyl may form a bonding association to the element M.

Each X in the formula (VI) above and for the formulas/structures (TI) through (V) below is independently selected from the group consisting of: any leaving group in one embodiment; halogen ions, hydrides, C₁ to C₁₂ alkyls, C₂ to C₁₂ alkenyls, C₆ to C₁₂ aryls, C₇ to C₂₀ alkylaryls, C₁ to C₁₂ alkoxys, C₆ to C₁₆ aryloxys, C₇ to C₁₈ alkylaryloxys, C₁ to C₁₂ fluoroalkyls, C₆ to C₁₂ fluoroaryls, and C₁ to C₁₂ heteroatom-containing hydrocarbons and substituted derivatives thereof in a more particular embodiment; hydride, halogen ions, C₁ to C₆ alkyls, C₂ to C₆ alkenyls, C₇ to C₁₈ alkylaryls, C₁ to C₆ alkoxys, C₆ to C₁₄ aryloxys, C₇ to C₁₆ alkylaryloxys, C₁ to C₆ alkylcarboxylates, C₁ to C₆ fluorinated alkylcarboxylates, C₆ to C₁₂ arylcarboxylates, C₇ to C₁₈ alkylarylcarboxylates, C₁ to C₆ fluoroalkyls, C₂ to C₆ fluoroalkenyls, and C₇ to C₁₈ fluoroalkylaryls in yet a more particular embodiment; hydride, chloride, fluoride, methyl, phenyl, phenoxy, benzoxy, tosyl, fluoromethyls and fluorophenyls in yet a more particular embodiment; C₁ to C₁₂ alkyls, C₂ to C₁₂ alkenyls, C₆ to C₁₂ aryls, C₇ to C₂₀ alkylaryls, substituted C₁ to C₁₂ alkyls, substituted C₆ to C₁₂ aryls, substituted C₇ to C₂₀ alkylaryls and C₁ to C₁₂ heteroatom-containing alkyls, C₁ to C₁₂ heteroatom-containing aryls and C₁ to C₁₂ heteroatom-containing alkylaryls in yet a more particular embodiment; chloride, fluoride, C₁ to C₆ alkyls, C₂ to C₆ alkenyls, C₇ to C₁₈ alkylaryls, halogenated C₁ to C₆ alkyls, halogenated C₂ to C₆ alkenyls, and halogenated C₇ to C₁₈ alkylaryls in yet a more particular embodiment; fluoride, methyl, ethyl, propyl, phenyl, methylphenyl, dimethylphenyl, trimethylphenyl, fluoromethyls (mono-, di- and trifluoromethyls) and fluorophenyls (mono-, di-, tri-, tetra- and pentafluorophenyls) in yet a more particular embodiment.

Other non-limiting examples of X groups in formula (VI) include amines, phosphines, ethers, carboxylates, dienes, hydrocarbon radicals having from 1 to 20 carbon atoms, fluorinated hydrocarbon radicals (e.g., —C₆F₅ (pentafluorophenyl)), fluorinated alkylcarboxylates (e.g., CF₃C(O)O⁻), hydrides and halogen ions and combinations thereof. Other examples of X ligands include alkyl groups such as cyclobutyl, cyclohexyl, methyl, heptyl, tolyl, trifluoromethyl, tetramethylene, pentamethylene, methylidene, methyoxy, ethyoxy, propoxy, phenoxy, bis(N-methylanilide), dimethylamide, dimethylphosphide radicals and the like. In one embodiment, two or more X's form a part of a fused ring or ring system.

In another aspect, the metallocene catalyst component includes those of formula (VI) where Cp^(A) and Cp^(B) are bridged to each other by at least one bridging group, (A), such that the structure is represented by formula (VII):

Cp^(A)(A)Cp^(B)MX_(n)

These bridged compounds represented by formula (VII) are known as “bridged metallocenes”. Cp^(A), Cp^(B), M, X and n in structure (VII) are as defined above for formula (VI); and wherein each Cp ligand is chemically bonded to M, and (A) is chemically bonded to each Cp. Non-limiting examples of bridging group (A) include divalent hydrocarbon groups containing at least one Group 13 to 16 atom, such as but not limited to at least one of a carbon, oxygen, nitrogen, silicon, aluminum, boron, germanium and tin atom and combinations thereof, wherein the heteroatom may also be C₁ to C₁₂ alkyl or aryl substituted to satisfy neutral valency. The bridging group (A) may also contain substituent groups R as defined above (for formula (VI)) including halogen radicals and iron. More particular non-limiting examples of bridging group (A) are represented by C₁ to C₆ alkylenes, substituted C₁ to C₆ alkylenes, oxygen, sulfur, R′₂C═, R′₂Si═, —Si(R′)₂Si(R′₂)—, R′₂Ge═, R′P═ (wherein “═” represents two chemical bonds), where R′ is independently selected from the group consisting of hydride, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, hydrocarbyl-substituted organometalloid, halocarbyl-substituted organometalloid, disubstituted boron, disubstituted Group 15 atoms, substituted Group 16 atoms, and halogen radical; and wherein two or more R′ may be joined to form a ring or ring system. In one embodiment, the bridged metallocene catalyst component of formula (VII) has two or more bridging groups (A).

Other non-limiting examples of bridging group (A) include methylene, ethylene, ethylidene, propylidene, isopropylidene, diphenylmethylene, 1,2-dimethylethylene, 1,2-diphenylethylene, 1,1,2,2-tetramethylethylene, dimethylsilyl, diethylsilyl, methyl-ethylsilyl, trifluoromethylbutylsilyl, bis(trifluoromethyl)silyl, di(n-butyl)silyl, di(n-propyl)silyl, di(1-propyl)silyl, di(n-hexyl)silyl, dicyclohexylsilyl, diphenylsilyl, cyclohexylphenylsilyl, t-butylcyclohexylsilyl, di(t-butylphenyl)silyl, di(p-tolyl)silyl and the corresponding moieties wherein the Si atom is replaced by a Ge or a C atom; dimethylsilyl, diethylsilyl, dimethylgermyl and diethylgermyl.

In another embodiment, bridging group (A) may also be cyclic, comprising, for example 4 to 10, 5 to 7 ring members in a more particular embodiment. The ring members may be selected from the elements mentioned above, from one or more of B, C, Si, Ge, N and O in a particular embodiment. Non-limiting examples of ring structures which may be present as or part of the bridging moiety are cyclobutylidene, cyclopentylidene, cyclohexylidene, cycloheptylidene, cyclooctylidene and the corresponding rings where one or two carbon atoms are replaced by at least one of Si, Ge, N and O, in particular, Si and Ge. The bonding arrangement between the ring and the Cp groups may be either cis-, trans-, or a combination.

The cyclic bridging groups (A) may be saturated or unsaturated and/or carry one or more substituents and/or be fused to one or more other ring structures. If present, the one or more substituents are selected from the group consisting of hydrocarbyl (e.g., alkyl such as methyl) and halogen (e.g., F, Cl) in one embodiment. The one or more Cp groups which the above cyclic bridging moieties may optionally be fused to may be saturated or unsaturated and are selected from the group consisting of those having 4 to 10, more particularly 5, 6 or 7 ring members (selected from the group consisting of C, N, O and S in a particular embodiment) such as, for example, cyclopentyl, cyclohexyl and phenyl. Moreover, these ring structures may themselves be fused such as, for example, in the case of a naphthyl group. Moreover, these (optionally fused) ring structures may carry one or more substituents. Illustrative, non-limiting examples of these substituents are hydrocarbyl (particularly alkyl) groups and halogen atoms.

The ligands Cp^(A) and Cp^(B) of formulae (VI) and (VII) are different from each other in one embodiment, and the same in another embodiment.

In yet another aspect, the metallocene catalyst components include mono-ligand metallocene compounds (e.g., mono cyclopentadienyl catalyst components) such as described in WO 93/08221 for example. In this embodiment, the at least one metallocene catalyst component is a bridged “half-sandwich” metallocene represented by the formula (VIII):

Cp^(A)(A)QMX_(n)

wherein Cp^(A) is defined above and is bound to M; (A) is a bridging group bonded to Q and Cp^(A); and wherein an atom from the Q group is bonded to M; and n is 0 or an integer from 1 to 3; 1 or 2 in a particular embodiment. In formula (VIII) above, Cp^(A), (A) and Q may form a fused ring system. The X groups and n of formula (VIII) are as defined above in formula (VI) and (VII). In one embodiment, Cp^(A) is selected from the group consisting of cyclopentadienyl, indenyl, tetrahydroindenyl, fluorenyl, substituted versions thereof, and combinations thereof.

In formula (VIII), Q is a heteroatom-containing ligand in which the bonding atom (the atom that is bonded with the metal M) is selected from the group consisting of Group 15 atoms and Group 16 atoms in one embodiment, and selected from the group consisting of nitrogen, phosphorus, oxygen or sulfur atom in a more particular embodiment, and nitrogen and oxygen in yet a more particular embodiment. Non-limiting examples of Q groups include alkylamines, arylamines, mercapto compounds, ethoxy compounds, carboxylates (e.g., pivalate), carbamates, azenyl, azulene, pentalene, phosphoyl, phosphinimine, pyrrolyl, pyrozolyl, carbazolyl, borabenzene other compounds comprising Group 15 and Group 16 atoms capable of bonding with M.

In yet another aspect, the at least one metallocene catalyst component is an unbridged “half sandwich” metallocene represented by the formula (IX):

Cp^(A)(A)QMX_(n)

wherein Cp^(A) is defined as for the Cp groups in (VI) and is a ligand that is bonded to M; each Q is independently bonded to M; Q is also bound to Cp^(A) in one embodiment; X is a leaving group as described above in (VI); n ranges from 0 to 3, and is 1 or 2 in one embodiment; q ranges from 0 to 3, and is 1 or 2 in one embodiment. In one embodiment, Cp^(A) is selected from the group consisting of cyclopentadienyl, indenyl, tetrahydroindenyl, fluorenyl, substituted version thereof, and combinations thereof.

In formula (IX), Q is selected from the group consisting of ROO⁻, RO—, R(O)—, —NR—, —CR₂—, —S—, —NR₂, —CR₃, —SR, —SiR₃, —PR₂, —H, and substituted and unsubstituted aryl groups, wherein R is selected from the group consisting of C₁ to C₆ alkyls, C₆ to C₁₂ aryls, C₁ to C₆ alkylamines, C₆ to C₁₂ alkylarylamines, C₁ to C₆ alkoxys, C₆ to C₁₂ aryloxys, and the like. Non-limiting examples of Q include C₁ to C₁₂ carbamates, C₁ to C₁₂ carboxylates (e.g., pivalate), C₂ to C₂₀ alkyls, and C₂ to C₂₀ heteroallyl moieties.

Described another way, the “half sandwich” metallocenes above can be described as in formula (X), such as described in, for example, U.S. Pat. No. 6,069,213:

Cp^(A)M(Q₂GZ)X_(n) or T(Cp^(A)M(Q₂GZ)X_(n))_(m)

wherein M, Cp^(A), X and n are as defined above;

Q₂GZ forms a polydentate ligand unit (e.g., pivalate), wherein at least one of the Q groups form a bond with M, and is defined such that each Q is independently selected from the group consisting of —O—, —NR—, —CR₂— and —S—; G is either carbon or silicon; and Z is selected from the group consisting of R, —OR, —NR₂, —CR₃, —SR, —SiR₃, —PR₂, and hydride, providing that when Q is —NR—, then Z is selected from the group consisting of —OR, —NR₂, —SR, —SiR₃, —PR₂; and provided that neutral valency for Q is satisfied by Z; and wherein each R is independently selected from the group consisting of C₁ to C₁₀ heteroatom containing groups, C₁ to C₁₀ alkyls, C₆ to C₁₂ aryls, C₆ to C₁₂ alkylaryls, C₁ to C₁₀ alkoxys, and C₆ to C₁₂ aryloxys;

n is 1 or 2 in a particular embodiment; and

T is a bridging group selected from the group consisting of C₁ to C₁₀ alkylenes, C₆ to C₁₂ arylenes and C₁ to C₁₀ heteroatom containing groups, and C₆ to C₁₂ heterocyclic groups; wherein each T group bridges adjacent “Cp^(A)M(Q₂GZ)X_(n)” groups, and is chemically bonded to the Cp^(A) groups.

m is an integer from 1 to 7; m is an integer from 2 to 6 in a more particular embodiment.

In another aspect, the at least one metallocene catalyst component can be described more particularly in structures (XIa), (XIb), (XIc), (XId) (XIe) and (XIf):

wherein in structures (XIa) to (XIf) M is selected from the group consisting of Group 3 to Group 12 atoms, and selected from the group consisting of Group 3 to Group 10 atoms in a more particular embodiment, and selected from the group consisting of Group 3 to Group 6 atoms in yet a more particular embodiment, and selected from the group consisting of Group 4 atoms in yet a more particular embodiment, and selected from the group consisting of Zr and Hf in yet a more particular embodiment; and is Zr in yet a more particular embodiment;

wherein Q in (XIa) to (XIf) is selected from the group consisting of alkylenes, aryls, arylenes, alkoxys, aryloxys, amines, arylamines (e.g., pyridyl) alkylamines, phosphines, alkylphosphines, substituted alkyls, substituted aryls, substituted alkoxys, substituted aryloxys, substituted amines, substituted alkylamines, substituted phosphines, substituted alkylphosphines, carbamates, heteroallyls, carboxylates (non-limiting examples of suitable carbamates and carboxylates include trimethylacetate, trimethylacetate, methylacetate, p-toluate, benzoate, diethylcarbamate, and dimethylcarbamate), fluorinated alkyls, fluorinated aryls, and fluorinated alkylcarboxylates; wherein the saturated groups defining Q comprise from 1 to 20 carbon atoms in one embodiment; and wherein the aromatic groups comprise from 5 to 20 carbon atoms in one embodiment;

wherein each R* is independently: selected from the group consisting of hydrocarbylenes and heteroatom-containing hydrocarbylenes in one embodiment; and selected from the group consisting of alkylenes, substituted alkylenes and heteroatom-containing hydrocarbylenes in another embodiment; and selected from the group consisting of C₁ to C₁₂ alkylenes, C₁ to C₁₂ substituted alkylenes, and C₁ to C₁₂ heteroatom-containing hydrocarbylenes in a more particular embodiment; and selected from the group consisting of C₁ to C₄ alkylenes in yet a more particular embodiment; and wherein both R* groups are identical in another embodiment in structures (XIf);

A is as described above for (A) in structure (VII), and more particularly, selected from the group consisting of a chemical bond, —O—, —S—, —SO₂—, —NR—, ═SiR₂, ═GeR₂, ═SnR₂, —R2SiSiR₂—, RP═, C₁ to C₁₂ alkylenes, substituted C₁ to C₁₂ alkylenes, divalent C₄ to C₁₂ cyclic hydrocarbons and substituted and unsubstituted aryl groups in one embodiment; and selected from the group consisting of C₅ to C₈ cyclic hydrocarbons, —CH₂CH₂—, ═CR₂ and ═SiR₂ in a more particular embodiment; wherein and R is selected from the group consisting of alkyls, cycloalkyls, aryls, alkoxys, fluoroalkyls and heteroatom-containing hydrocarbons in one embodiment; and R is selected from the group consisting of C₁ to C₆ alkyls, substituted phenyls, phenyl, and C₁ to C₆ alkoxys in a more particular embodiment; and R is selected from the group consisting of methoxy, methyl, phenoxy, and phenyl in yet a more particular embodiment;

wherein A may be absent in yet another embodiment, in which case each R* is defined as for R¹ R¹³;

each X is as described above in (VI);

n is an integer from 0 to 4, and from 1 to 3 in another embodiment, and 1 or 2 in yet another embodiment; and

R¹ through R¹³ are independently: selected from the group consisting of hydrogen radical, halogen radicals, C₁ to C₁₂ alkyls, C₂ to C₁₂ alkenyls, C₆ to C₁₂ aryls, C₇ to C₂₀ alkylaryls, C₁ to C₁₂ alkoxys, C₁ to C₁₂ fluoroalkyls, C₆ to C₁₂ fluoroaryls, and C₁ to C₁₂ heteroatom-containing hydrocarbons and substituted derivatives thereof in one embodiment; selected from the group consisting of hydrogen radical, fluorine radical, chlorine radical, bromine radical, C₁ to C₆ alkyls, C₂ to C₆ alkenyls, C₇ to C₁₅ alkylaryls, C₁ to C₆ fluoroalkyls, C₂ to C₆ fluoroalkenyls, C₇ to C₁₅ fluoroalkylaryls in a more particular embodiment; and hydrogen radical, fluorine radical, chlorine radical, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tertiary butyl, hexyl, phenyl, 2,6-di-methylpheyl, and 4-tertiarbutylpheyl groups in yet a more particular embodiment; wherein adjacent R groups may form a ring, either saturated, partially saturated, or completely saturated.

The structure of the metallocene catalyst component represented by (XIa) may take on many forms such as disclosed in, for example, U.S. Pat. Nos. 5,026,798, 5,703,187, and 5,747,406, including a dimer or oligomeric structure, such as disclosed in, for example, U.S. Pat. Nos. 5,026,798 and 6,069,213.

In a particular embodiment of the metallocene represented in (XId), R¹ and R² form a conjugated 6-membered carbon ring system that may or may not be substituted.

Non-limiting examples of metallocene catalyst components consistent with the description herein include: cyclopentadienylzirconium X_(n), indenylzirconium X_(n), (1-methylindenyl)zirconium X_(n), (2-methylindenyl)zirconium X_(n), (1-propylindenyl)zirconium X_(n), (2-propylindenyl)zirconium X_(n), (1-butylindenyl)zirconium X_(n), (2-butylindenyl)zirconium X_(n), (methylcyclopentadienyl)zirconium X_(n), tetrahydroindenylzirconium X_(n), (pentamethylcyclopentadienyl)zirconium X_(n), cyclopentadienylzirconium X_(n), pentamethylcyclopentadienyltitanium X_(n), tetramethylcyclopentyltitanium X_(n), 1,2,4-trimethylcyclopentadienylzirconium X_(n), dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(cyclopentadienyl)zirconium X_(n), dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(1,2,3-trimethylcyclopentadienyl)zirconium X_(n), dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(1,2-dimethylcyclopentadienyl)zirconium X_(n), dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(2-methylcyclopentadienyl)zirconium X_(n), dimethylsilyl(cyclopentadienyl)(indenyl)zirconium X_(n), dimethylsilyl(2-methylindenyl)(fluorenyl)zirconium X_(n), diphenylsilyl(1,2,3,4-tetramethyl-cyclopentadienyl)(3-propylcyclopentadienyl)zirconium X_(n), dimethylsilyl (1,2,3,4-tetramethylcyclopentadienyl)(3-t-butylcyclopentadienyl)zirconium X_(n), dimethylgermyl(1,2,3,4-dimethylcyclopentadienyl)(3-isopropylcyclopentadienyl)zirconium X_(n), dimethylsilyl(1,2,3,4-tetramethyl-cyclopentadienyl)(3-methylcyclopentadienyl)zirconium X_(n), diphenylmethylidene(cyclopentadienyl)(9-fluorenyl)zirconium X_(n), diphenylmethylidene(cyclopentadienyl)(indenyl)zirconium X_(n), iso-propylidenebis(cyclopentadienyl)zirconium X_(n), iso-propylidene(cyclopentadienyl)(9-fluorenyl)zirconium X_(n), iso-propylidene(3-methylcyclopentadienyl)(9-fluorenyl)zirconium X_(n), ethylenebis(9-fluorenyl)zirconium X_(n), meso-ethylenebis(1-indenyl)zirconium X_(n), ethylenebis(1-indenyl)zirconium X_(n), ethylenebis(2-methyl-1-indenyl)zirconium X_(n), ethylenebis(2-methyl-4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), ethylenebis(2-propyl-4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), ethylenebis(2-isopropyl-4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), ethylenebis(2-butyl-4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), ethylenebis(2-isobutyl-4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), dimethylsilyl(4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), diphenyl(4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), ethylenebis(4,5,6,7-tetrahydro-1-indenyl)zirconium X_(n), dimethylsilylbis(cyclopentadienyl)zirconium X_(n), dimethylsilylbis(9-fluorenyl)zirconium X_(n), dimethylsilylbis(1-indenyl)zirconium X_(n), dimethylsilylbis(2-methylindenyl)zirconium X_(n), dimethylsilylbis(2-propylindenyl)zirconium X_(n), dimethylsilylbis(2-butylindenyl)zirconium X_(n), diphenylsilylbis(2-methylindenyl)zirconium X_(n), diphenylsilylbis(2-propylindenyl)zirconium X_(n), diphenylsilylbis(2-butylindenyl)zirconium X_(n), dimethylgermylbis(2-methylindenyl)zirconium X_(n) dimethylsilylbis(tetrahydroindenyl)zirconium X_(n), dimethylsilylbis(tetramethylcyclopentadienyl) zirconium X_(n), dimethylsilyl(cyclopentadienyl)(9-fluorenyl)zirconium X_(n), diphenylsilyl (cyclopentadienyl) (9-fluorenyl)zirconium X_(n), diphenylsilylbis(indenyl)zirconium X_(n), cyclotrimethylenesilyl(tetramethylcyclopentadienyl)(cyclopentadienyl)zirconium X_(n), cyclotetramethylenesilyl(tetramethylcyclopentadienyl)(cyclopentadienyl)zirconium X_(n), cyclotrimethylenesilyl(tetramethylcyclopentadienyl)(2-methylindenyl)zirconium X_(n), cyclotrimethylenesilyl(tetramethylcyclopentadienyl)(3-methylcyclopentadienyl)zirconium X_(n), cyclotrimethylenesilylbis(2-methylindenyl)zirconium X_(n), cyclotrimethylenesilyl (tetramethylcyclopentadienyl)(2,3,5-trimethylcyclopentadienyl)zirconium X_(n), cyclotrimethylenesilylbis(tetramethylcyclopentadienyl)zirconium X_(n), dimethylsilyl(tetramethylcyclopentadieneyl)(N-tert-butylamido)titanium X_(n), bis(cyclopentadienyl)chromium X_(n), bis(cyclopentadienyl)zirconium X_(n), bis(n-butylcyclopentadienyl)zirconium X_(n), bis(n-dodecyclcyclopentadienyl)zirconium X_(n), bis(ethylcyclopentadienyl)zirconium X_(n), bis(iso-butylcyclopentadienyl)zirconium X_(n), bis(iso-propylcyclopentadienyl)zirconium X_(n), bis(methylcyclopentadienyl)zirconium X_(n), bis(n-oxtylcyclopentadienyl)zirconium X_(n), bis(n-pentylcyclopentadienyl)zirconium X_(n), bis(n-propylcyclopentadienyl)zirconium X_(n), bis(trimethylsilylcyclopentadienyl)zirconium X_(n), bis(1,3-bis(trimethylsilyl)cyclopentadienyl)zirconium X_(n), bis(1-ethyl-2-methylcyclopentadienyl)zirconium X_(n), bis(1-ethyl-3-methylcyclopentadienyl)zirconium X_(n), bis(pentamethylcyclopentadienyl) zirconium X_(n), bis(pentamethylcyclopentadienyl)zirconium X_(n), bis(1-propyl-3-methylcyclopentadienyl) zirconium X_(n), bis(1-n-butyl-3-methylcyclopentadienyl)zirconium X_(n), bis(1-isobutyl-3-methylcyclopentadienyl)zirconium X_(n), bis(1-propyl-3-butylcyclopentadienyl) zirconium X_(n), bis(1,3-n-butylcyclopentadienyl)zirconium X_(n), bis(4,7-dimethylindenyl)zirconium X_(n), bis(indenyl)zirconium X_(n), bis(2-methylindenyl)zirconium X_(n), cyclopentadienylindenylzirconium X_(n), bis(n-propylcyclopentadienyl)hafnium X_(n), bis(n-butylcyclopentadienyl)hafniium X_(n), bis(n-pentylcyclopentadienyl) hafnium X_(n), (n-propyl cyclopentadienyl)(n-butyl cyclopentadienyl)hafnium X_(n), bis[(2-trimethylsilylethyl)cyclopentadienyl]hafnium X_(n), bis(trimethylsilyl cyclopentadienyl) hafnium X_(n), bis(2-n-propylindenyl)hafnium X_(n), bis(2-n-butylindenyl)hafnium X_(n), dimethylsilylbis(n-propylcyclopentadienyl)hafnium X_(n), dimethylsilylbis(n-butylcyclopentadienyl) hafnium X_(n), bis(9-n-propylfluorenyl)hafnium X_(n), bis(9-n-butylfluorenyl)hafnium X_(n), (9-n-propylfluorenyl) (2-n-propylindenyl)hafnium X_(n), bis(1-n-propyl-2-methylcyclopentadienyl)hafnium X_(n), (n-propylcyclopentadienyl)(1-n-propyl-3-n-butylcyclopentadienyl)hafnium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(cyclopropylamido)titanium X_(n), dimethylsilyl(tetramethyleyclopentadienyl) (cyclobutylamido)titanium X_(n), dimethylsilyl(tetramethyleyclopentadienyl) (cyclopentylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl) (cyclohexylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl) (cycloheptylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(cyclooctylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(cyclononylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(cyclodecylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(cycloundecylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(cyclododecylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(sec-butylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(n-octylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(n-decylamido)titanium X_(n), dimethylsilyl(tetramethylcyclopentadienyl)(n-octadecylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclopropylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclobutylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclopentylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclohexylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cycloheptylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclooctylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclononylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclodecylamido)titanium, X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cycloundecylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(cyclododecylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(sec-butylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(n-octylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(n-decylamido)titanium X_(n), methylphenylsilyl(tetramethylcyclopentadienyl)(n-octadecylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclopropylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclobutylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclopentylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclohexylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cycloheptylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclooctylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclononylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclodecylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cycloundecylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(cyclododecylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(sec-butylamido)titanium X_(n), diphenylsilyl(tetramethyleyclopentadienyl)(n-octylamido)titanium X_(n), diphenylsilyl(tetramethyleyclopentadienyl)(n-decylamido)titanium X_(n), diphenylsilyl(tetramethylcyclopentadienyl)(n-octadecylamido)titanium X_(n), and derivatives thereof.

By “derivatives thereof” or “derivatives of”, it is meant any substitution or ring formation as described above in one embodiment; and in particular, replacement of the metal “M” (Cr, Zr, Ti or Hf) with an atom selected from the group consisting of Cr, Zr, Hf and Ti; and replacement of the “X” group with any of C₁ to C₅ alkyls, C₆ aryls, C₆ to C₁₀ alkylaryls, fluorine or chlorine; n is 1, 2 or 3.

It is contemplated that the metallocene catalysts components described above include their structural or optical or enantiomeric isomers (racemic mixture), and may be a pure enantiomer in one embodiment.

As used herein, a single, bridged, asymmetrically substituted metallocene catalyst component having a racemic and/or meso isomer does not, itself, constitute at least two different bridged, metallocene catalyst components.

The “metallocene catalyst component” may comprise any combination of any “embodiment” described herein.

Group 15-Containing Catalyst Compositions

“Group 15-containing catalyst components”, as referred to herein, include Group 3 to Group 12 metal complexes, wherein the metal is 2 to 4 coordinate, the coordinating moiety or moieties including at least two Group 15 atoms, and up to four Group 15 atoms. In one embodiment, the Group 15-containing catalyst component is a complex of a Group 4 metal and from one to four ligands such that the Group 4 metal is at least 2 coordinate, the coordinating moiety or moieties including at least two nitrogens. Representative Group 15-containing compounds are disclosed in, for example, WO 98/46651, WO 99/01460; EP A10 893,454; EP A10 894 005; U.S. Pat. Nos. 5,318,935; 5,889,128 6,333,389 B2 and 6,271,325 B1.

In one embodiment, the Group 15-containing catalyst components may include Group 4 imino-phenol complexes, Group 4 bis(amide) complexes, and Group 4 pyridyl-amide complexes that are active towards olefin polymerization to any extent.

The Group 15-containing catalyst component may be more particularly described by the following formula (XII):

α_(a)β_(b)γ_(g)MX_(n)  (XII)

wherein beta (β) and gamma (γ) are groups that each comprise at least one Group 14 to Group 16 atom; and beta (when present) and gamma are groups bonded to M through between 2 and 6 Group 14 to Group 16 atoms, at least two atoms being Group 15-containing atoms.

More particularly, beta and gamma are groups selected from Group 14 and Group 15-containing: alkyls, aryls, alkylaryls, and heterocyclic hydrocarbons, and chemically bonded combinations thereof in one embodiment; and selected from Group 14 and Group 15-containing: C₁ to C₁₀ alkyls, C₆ to C₁₂ aryls, C₆ to C₁₅ alkylaryls, and C₄ to C₁₂ heterocyclic hydrocarbons, and chemically bonded combinations thereof in a more particular embodiment; and selected from C₁ to C₁₀ alkylamines, C₁ to C₁₀ alkoxys, C₆ to C₂₀ alkylarylamines, C₆ to C₁₅ alkylaryloxys, and C₄ to C₁₂ nitrogen containing heterocyclic hydrocarbons, and C₄ to C₁₂ alkyl substituted nitrogen containing heterocyclic hydrocarbons and chemically bonded combinations thereof in yet a more particular embodiment; and selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, indolyls, C₁ to C₆ alkyl substituted groups selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, indolyls; C₁ to C₆ alkylamine substituted groups selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, indolyls, amine substituted anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, and indolyls; hydroxy substituted groups selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, and indolyls; methyl-substituted phenylamines, and chemically bonded combinations thereof in yet a more particular embodiment;

alpha (α) is a linking (or “bridging”) moiety that, when present, forms a chemical bond to each of beta and gamma, or two gamma's, thus forming a “gamma alpha gamma” or “gamma alpha beta” ligand bound to M; alpha may also comprise a Group 14 to Group 16 atom which may be bonded to M through the Group 14 to Group 16 atom in one embodiment; and more particularly, a is a divalent bridging group selected from alkylenes, arylenes, alkenylenes, heterocyclic arylenes, alkylarylenes, heteroatom containing alkylenes, heteroatom containing alkenylenes and heterocyclic hydrocarbonylenes in one embodiment; and selected from C₁ to C₁₀ alkylenes, C₂ to C₁₀ alkenylenes, C₆ to C₁₂ arylenes, C₁ to C₁₀ divalent ethers, C₆ to C₁₂ O- or N-containing arylenes, C₂ to C₁₀ alkyleneamines, C₆ to C₁₂ aryleneamines, and substituted derivatives thereof in yet a more particular embodiment;

a is an integer from 0 to 2; a is either 0 or 1 in a more particular embodiment; and a is 1 in yet a more particular embodiment; b is an integer from 0 to 2; g is an integer from 1 to 2; wherein in one embodiment, a is 1, b is 0 and g is 2; M is selected from Group 3 to Group 12 atoms in one embodiment; and selected from Group 3 to Group 10 atoms in a more particular embodiment; and selected from Group 3 to Group 6 atoms in yet a more particular embodiment; and selected from Ni, Cr, Ti, Zr and Hf in yet a more particular embodiment; and selected from Zr and Hf in yet a more particular embodiment; each X is as defined above; and n is an integer from 0 to 4 in one embodiment; and an integer from 1 to 3 in a more particular embodiment; and an integer from 2 to 3 in yet a more particular embodiment.

As used herein, “chemically bonded combinations thereof” means that adjacent groups, (beta and gamma groups) may form a chemical bond between them; in one embodiment, the beta and gamma groups are chemically bonded through one or more a groups there between.

As used herein, the terms “alkyleneamines”, “aryleneamines”, describe alkylamines and arylamines (respectively) that are deficient by two hydrogens, thus forming chemical bonds with two adjacent gamma groups, or adjacent beta. and gamma groups. Thus, an example of an alkyleneamine is —CH₂CH₂N(CH₃)CH₂CH₂—, and an example of a heterocyclic hydrocarbylene or aryleneamine is —C₅H₃N— (divalent pyridine). An “alkylene-arylamine” is a group such as, for example, —CH₂CH₂(C₅H₃N)CH₂CH₂—.

Described another way, the Group 15-containing catalyst component is represented by the structures (XIII) and (XIV):

wherein E and Z are Group 15 elements independently selected from nitrogen and phosphorus in one embodiment; and nitrogen in a more particular embodiment;

L is selected from Group 15 atoms, Group 16 atoms, Group 15-containing hydrocarbylenes and a Group 16 containing hydrocarbylenes in one embodiment; wherein R³ is absent when L is a Group 16 atom; in yet a more particular embodiment, when R³ is absent, L is selected from heterocyclic hydrocarbylenes; and in yet a more particular embodiment, L is selected from nitrogen, phosphorous, anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, indolyls; C₁ to C₆ alkyl substituted groups selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, and indolyls; C₁ to C₆ alkylamine substituted groups selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, indolyls; amine substituted anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, and indolyls; hydroxy substituted groups selected from anilinyls, pyridyls, quinolyls, pyrrolyls, pyrimidyls, purinyls, imidazyls, and indolyls; methyl-substituted phenylamines, substituted derivatives thereof, and chemically bonded combinations thereof,

L′ is selected from Group 15 atoms, Group 16 atoms, and Group 14 atoms in one embodiment; and selected from Group 15 and Group 16 atoms in a more particular embodiment; and is selected from groups as defined by L above in yet a more particular embodiment, wherein “EZL” and “EZL”. may be referred to as a “ligand”, the EZL and EZL′ ligands comprising the R* and R¹, R⁷ groups;

wherein L and L′ may or may not form a bond with M;

y is an integer ranging from 0 to 2 (when y is 0, group L′, *R and R³ are absent);

M is selected from Group 3 to Group 5 atoms, Group 4 atoms in a more particular embodiment, and selected from Zr and Hf in yet a more particular embodiment;

n is an integer ranging from 1 to 4 in one embodiment; n is an integer ranging from 2 to 3 in a more particular embodiment;

each X is as defined above;

R¹ and R² are independently: divalent bridging groups selected from alkylenes, arylenes, heteroatom containing alkylenes, heteroatom containing arylenes, substituted alkylenes, substituted arylenes and substituted heteroatom containing alkylenes, wherein the heteroatom is selected from silicon, oxygen, nitrogen, germanium, phosphorous, boron and sulfur in one embodiment; selected from C₁ to C₂₀ alkylenes, C₆ to C₁₂ arylenes, heteroatom-containing C₁ to C₂₀ alkylenes and heteroatom-containing C₆ to C₁₂ arylenes in a more particular embodiment; and in yet a more particular embodiment selected from —CH₂—, —C(CH₃)₂—, —C(C₆H₅)—, —CH₂CH₂—, —CH₂CH₂CH₂—, —Si(CH₃)₂—, —Si(C₆H₅)₂—, —C₆H₁₀—, —C₆H₄—, and substituted derivatives thereof, the substitutions including C₁ to C₄ alkyls, phenyl, and halogen radicals;

R³ is absent in one embodiment; a group selected from hydrocarbyl groups, hydrogen radical, halogen radicals, and heteroatom-containing groups in a more particular embodiment; and selected from linear alkyls, cyclic alkyls, and branched alkyls having 1 to 20 carbon atoms in yet a more particular embodiment;

*R is absent in one embodiment; a group selected from hydrogen radical, Group 14 atom containing groups, halogen radicals, and a heteroatom-containing groups in yet a more particular embodiment;

R⁴ and R⁵ are independently: groups selected from alkyls, aryls, substituted aryls, cyclic alkyls, substituted cyclic alkyls, cyclic arylalkyls, substituted cyclic arylalkyls and multiple ring systems in one embodiment, each group having up to 20 carbon atoms, and between 3 and 10 carbon atoms in a more particular embodiment; selected from C₁ to C₂₀ alkyls, C₁ to C₂₀ aryls, C₁ to C₂₀ arylalkyls, and heteroatom-containing groups (for example PR₃, where R is an alkyl group) in yet a more particular embodiment; and

R⁶ and R⁷ are independently: absent in one embodiment; groups selected from hydrogen radicals, halogen radicals, heteroatom-containing groups and hydrocarbyls in a more particular embodiment; selected from linear, cyclic and branched alkyls having from 1 to 20 carbon atoms in yet a more particular embodiment;

wherein R¹ and R² may be associated with one another, and/or R⁴ and R⁵ may be associated with one another as through a chemical bond.

Described yet more particularly, the Group 15-containing catalyst component can be described as the embodiments shown in structures (IV), (V) and (VI) (where “N” is nitrogen):

wherein structure (XV) represents pyridyl-amide structures, structure (XVI) represents imino-phenol structures, and structure (XVII) represents bis(amide) structures; wherein w is an integer from 1 to 3, and 1 or 2 in a more particular embodiment, and 1 in yet a more particular embodiment; M is a Group 3 to Group 13 element, a Group 3 to Group 6 element in a more particular embodiment, and a Group 4 element in yet a more particular embodiment; each X is independently selected from hydrogen radicals, halogen ions (desirably, anions of fluorine, chlorine, and bromine); C₁ to C₆ alkyls; C₁ to C₆ fluoroalkyls, C₆ to C₁₂ aryls; C₆ to C₁₂ fluoroalkyls, C₁ to C₆ alkoxys, C₆ to C₁₂ aryloxys, and C₇ to C₁₈ alkylaryloxys; n is an integer ranging from 0 to 4, and from 1 to 3 in a more particular embodiment, and from 2 to 3 in yet a more particular embodiment, and 2 in yet a more particular embodiment;

and further, wherein in structures (XV), (XVI) and (XVII), R^(1′) is selected from hydrocarbylenes and heteroatom-containing hydrocarbylenes in one embodiment, and selected from —SiR₂—, alkylenes, arylenes, alkenylenes and substituted alkylenes, substituted alkenylenes and substituted arylenes in another embodiment; and selected from —SiR₂—, C₁ to C₆ alkylenes, C₆ to C₁₂ arylenes, C₁ to C₆ substituted alkylenes and C₆ to C₁₂ substituted arylenes in another embodiment, wherein R is selected from C₁ to C₆ alkyls and C₆ to C₁₂ aryls; and

R^(2′), R^(3′), R^(4′), R^(5′), R^(6′) and R* are independently selected from hydride, C₁ to C₁₀ alkyls, C₆ to C₁₂ aryls, C₆ to C₁₈ alkylaryls, C₄ to C₁₂ heterocyclic hydrocarbyls, substituted C₁ to C₁₀ alkyls, substituted C₆ to C₁₂ aryls, substituted C₆ to C₁₈ alkylaryls, and substituted C₄ to C₁₂ heterocyclic hydrocarbyls and chemically bonded combinations thereof in one embodiment; wherein R* is absent in a particular embodiment; and in another embodiment, R*—N represents a nitrogen containing group or ring such as a pyridyl group or a substituted pyridyl group that is bridged by the R¹ groups. In yet another embodiment, R*—N is absent, and the R¹ groups form a chemical bond to one another.

In one embodiment of structures (XV), (XVI) and (XVII), R^(1′) is selected from methylene, ethylene, 1-propylene, 2-propylene, ═Si(CH₃)₂, ═Si(phenyl)₂, —CH═, —C(CH₃)═, —C(phenyl)₂-, —C(phenyl)=(wherein “═” represents two chemical bonds), and the like.

In a particular embodiment of structure (XVI), R^(2′) and R^(4′) are selected from 2-methylphenyl, 2-n-propylphenyl, 2-iso-propylphenyl, 2-iso-butylphenyl, 2-tert-butylphenyl, 2-fluorophenyl, 2-chlorophenyl, 2-bromophenyl, 2-methyl-4-chlorophenyl, 2-n-propyl-4-chlorophenyl, 2-iso-propyl-4-chlorophenyl, 2-iso-butyl-4-chlorophenyl, 2-tert-butyl-4-chlorophenyl, 2-methyl-4-fluorophenyl, 2-n-propyl-4-fluorophenyl, 2-iso-propyl-4-fluorophenyl, 2-iso-butyl-4-fluorophenyl, 2-tert-butyl-4-fluorophenyl, 2-methyl-4-bromophenyl, 2-n-propyl-4-bromophenyl, 2-iso-propyl-4-bromophenyl, 2-iso-butyl-4-bromophenyl, 2-tert-butyl-4-bromophenyl, and the like.

In yet another particular embodiment of structures (XV) and (XVII), R^(2′) and R^(3′) are selected from 2-methylphenyl, 2-n-propylphenyl, 2-iso-propylphenyl, 2-iso-butylphenyl, 2-tert-butylphenyl, 2-fluorophenyl, 2-chlorophenyl, 2-bromophenyl, 4-methylphenyl, 4-n-propylphenyl, 4-iso-propylphenyl, 4-iso-butylphenyl, 4-tert-butylphenyl, 4-fluorophenyl, 4-chlorophenyl, 4-bromophenyl, 6-methylphenyl, 6-n-propylphenyl, 6-iso-propylphenyl, 6-iso-butylphenyl, 6-tert-butylphenyl, 6-fluorophenyl, 6-chlorophenyl, 6-bromophenyl, 2,6-dimethylphenyl, 2,6-di-n-propylphenyl, 2,6-di-iso-propylphenyl, 2,6-di-isobutylphenyl, 2,6-di-tert-butylphenyl, 2,6-difluorophenyl, 2,6-dichlorophenyl, 2,6-dibromophenyl, 2,4,6-trimethylphenyl, 2,4,6-tri-n-propylphenyl, 2,4,6-tri-iso-propylphenyl, 2,4,6-tri-iso-butylphenyl, 2,4,6-tri-tert-butylphenyl, 2,4,6-trifluorophenyl, 2,4,6-trichlorophenyl, 2,4,6-tribromophenyl, 2,3,4,5,6-pentafluorophenyl, 2,3,4,5,6-pentachlorophenyl, 2,3,4,5,6-pentabromophenyl, and the like.

In another embodiment of structures (XV), (XVI) and (XVII), X is independently selected from fluoride, chloride, bromide, methyl, ethyl, phenyl, benzyl, phenyloxy, benzyloxy, 2-phenyl-2-propoxy, 1-phenyl-2-propoxy, 1-phenyl-2-butoxy, 2-phenyl-2-butoxy and the like.

As used herein, “chemically bonded combinations” means that adjacent groups may form a chemical bond between them, thus forming a ring system, either saturated, partially unsaturated, or aromatic.

Non-limiting examples of the Group 15-containing catalyst component are represented by the structures (XVIIIa) through (XVIIIf) (where “N” is nitrogen):

wherein in structures (XVIIIa) through (XVIIIf) M is selected from Group 4 atoms in one embodiment; and M is selected from Zr and Hf in a more particular embodiment; and wherein R¹ through R¹¹ structures (XVIIIa) through (XVIIIf) are selected from hydride, fluorine radical, chlorine radical, bromine radical, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl and phenyl; and X is selected from fluorine ion, chlorine ion, bromine ion, methyl, phenyl, benzyl, phenyloxy and benzyloxy; and n is an integer ranging from 0 to 4, and from 2 to 3 in a more particular embodiment.

The Group 15-containing catalyst components are prepared by methods known in the art, such as those disclosed in, for example, EP 0 893 454 A1, U.S. Pat. Nos. 5,889,128, 6,333,389 B2 and WO 00/37511.

The “Group 15-containing catalyst component” may comprise any combination of any “embodiment” described herein.

Phenoxide Transition Metal Catalyst Compositions

Phenoxide transition metal catalyst compositions are heteroatom substituted phenoxide ligated Group 3 to 10 transition metal or lanthanide metal compounds wherein the metal is bound to the oxygen of the phenoxide group. Phenoxide transition metal catalyst compounds may be represented by Formula XIX or XX:

wherein R¹ is hydrogen or a C₄ to C₁₀₀ group, preferably a tertiary alkyl group, preferably a C₄ to C₂₀ alkyl group, preferably a C₄ to C₂₀ tertiary alkyl group, preferably a neutral C₄ to C₁₀₀ group and may or may not also be bound to M;

at least one of R² to R⁵ is a heteroatom containing group, the rest of R² to R⁵ are independently hydrogen or a C₁ to C₁₀₀ group, preferably a C₄ to C₂₀ alkyl group, preferred examples of which include butyl, isobutyl, t-butyl, pentyl, hexyl, heptyl, isohexyl, octyl, isooctyl, decyl, nonyl, dodecyl, and any of R² to R⁵ also may or may not be bound to M;

Each R¹ to R⁵ group may be independently substituted or unsubstituted with other including heteroatoms or heteroatom containing group(s);

O is oxygen;

M is a Group 3 to Group 10 transition metal or lanthanide metal, preferably a Group 4 metal, preferably M is Ti, Zr or Hf,

n is the valence state of the metal M, preferably 2, 3, 4, or 5; and

Q is, and each Q may be independently be, an alkyl, halogen, benzyl, amide, carboxylate, carbamate, thiolate, hydride or alkoxide group, or a bond to an R group containing a heteroatom which may be any of R¹ to R⁵.

A heteroatom containing group may be any heteroatom or a heteroatom bound to carbon, silicon or another heteroatom. Preferred heteroatoms include boron, aluminum, silicon, nitrogen, phosphorus, arsenic, tin, lead, antimony, oxygen, selenium, and tellurium. Particularly preferred heteroatoms include nitrogen, oxygen, phosphorus, and sulfur. Even more particularly preferred heteroatoms include nitrogen and oxygen. The heteroatom itself may be directly bound to the phenoxide ring or it may be bound to another atom or atoms that are bound to the phenoxide ring. The heteroatom containing group may contain one or more of the same or different heteroatoms. Preferred heteroatom containing groups include imines, amines, oxides, phosphines, ethers, ketones, oxoazolines heterocyclics, oxazolines, thioethers, and the like. Particularly preferred heteroatom containing groups include imines. Any two adjacent R groups may form a ring structure, preferably a 5 or 6 membered ring. Likewise the R groups may form multi-ring structures. In one embodiment any two or more R groups do not form a 5 membered ring.

In a preferred embodiment the heteroatom substituted phenoxide transition metal compound is an iminophenoxide Group 4 transition metal compound, and more preferably an iminophenoxidezirconium compound.

Supported Catalyst Systems

The activator and/or the polymerization catalyst compound may be combined with one or more support materials or carriers using any one of the support methods known in the art or as described below. In one embodiment the activator is in a supported form, for example deposited on, contacted with, vaporized with, bonded to, or incorporated within, adsorbed or absorbed in, or on, a support or carrier. In another embodiment, the activator and a catalyst compound may be deposited on, contacted with, vaporized with, bonded to, or incorporated within, adsorbed or absorbed in, or on, a support or carrier.

The terms “support” or “carrier” for purposes of this patent specification are used interchangeably and are any support material, preferably a porous support material, including inorganic or organic support materials. Non-limiting examples of inorganic support materials include inorganic oxides and inorganic chlorides. Other carriers include resinous support materials such as polystyrene, functionalized or crosslinked organic supports, such as polystyrene, divinyl benzene, polyolefins, or polymeric compounds, zeolites, talc, clays, or any other organic or inorganic support material and the like, or mixtures thereof.

In one embodiment, the heterocyclic compounds and the alumoxanes described above are combined with one or more support materials or carriers. In another embodiment the heterocyclic compound is combined with a support material, preferably silica, treated with the alumoxane compound, such that the support has aluminum alkyl groups bonded thereto. The supported catalyst systems described herein may be prepared, generally, by the reaction of the heterocyclic compound with an alumoxane, the addition of the catalyst precursor, followed by addition of a support material such as silica or alumina.

The support materials utilized may be any of the conventional support materials. Preferably the supported material is a porous support material, for example, talc, inorganic oxides and inorganic chlorides. Other support materials include resinous support materials such as polystyrene, functionalized or crosslinked organic supports, such as polystyrene divinyl benzene polyolefins or polymeric compounds, zeolites, clays, or any other organic or inorganic support material and the like, or mixtures thereof.

The preferred support materials are inorganic oxides that include those Group 2, 3, 4, 5, 13 or 14 metal oxides. The preferred supports include silica, fumed silica, alumina, silica-alumina and mixtures thereof. Other useful supports include magnesia, titania, zirconia, magnesium chloride, montmorillonite, phyllosilicate, zeolites, talc, clays and the like. Also, combinations of these support materials may be used, for example, silica-chromium, silica-alumina, silica-titania and the like. Additional support materials may include those porous acrylic polymers. Other support materials include nanocomposites, aerogels, spherulites, and polymeric beads. Another support is fumed silica available under the trade name Cabosil™. TS-610, available from Cabot Corporation. Fumed silica is typically a silica with particles 7 to 30 nanometers in size that has been treated with dimethylsilyldichloride such that a majority of the surface hydroxyl groups are capped.

In another embodiment, any of the conventionally known inorganic oxides, such as silica, support materials that retain hydroxyl groups after dehydration treatment methods will be suitable in accordance with the invention. Because of availability, both of silica and silica containing metal oxide based supports, for example, silica-alumina, are preferred. Silica particles, gels and glass beads are most typical.

These metal oxide compositions may additionally contain oxides of other metals, such as those of Al, K, Mg, Na, Si, Ti and Zr and should preferably be treated by thermal and/or chemical means to remove water and free oxygen. Typically such treatment is in a vacuum in a heated oven, in a heated fluidized bed or with dehydrating agents such as organo silanes, siloxanes, alkyl aluminum compounds, etc. The level of treatment should be such that as much retained moisture and oxygen as is possible is removed, but that a chemically significant amount of hydroxyl functionality is retained. Thus calcining at up to 800 degree C. or more up to a point prior to decomposition of the support material, for several hours is permissible, and if higher loading of supported anionic activator is desired, lower calcining temperatures for lesser times will be suitable. Where the metal oxide is silica, loadings to achieve from less than 0.1 mmol to 3.0 mmol activator/g SiO₂ are typically suitable and can be achieved, for example, by varying the temperature of calcining from 200° C. to 1,000° C., such as from 300° C. to 900° C., 400° C. to 875° C., 500° C. to 850° C., 600° C. to 825° C., 700° C. to 800° C., and any combination of any limit with any lower limit.

The tailoring of hydroxyl groups available as attachment sites in this invention can also be accomplished by the pre-treatment with a less than stoichiometric amount of a chemical dehydrating agent. If calcining temperatures below 400 degree C. are employed, difunctional coupling agents (e.g., (CH₃)₃SiCl₂) may be employed to cap hydrogen bonded pairs of silanol groups which are present under the less severe calcining conditions. Similarly, use of the Lewis acid in excess of the stoichiometric amount needed for reaction with the transition metal compounds will serve to neutralize excess silanol groups without significant detrimental effect for catalyst preparation or subsequent polymerization.

In another embodiment, the support is a polymeric support, including hydroxyl-functional-group-containing polymeric substrates, but functional groups may be any of the primary alkyl amines, secondary alkyl amines, and others, where the groups are structurally incorporated in a polymeric chain and capable of a acid-base reaction with the Lewis acid such that a ligand filling one coordination site of the aluminum is protonated and replaced by the polymer incorporated functionality. See, for example, the functional group containing polymers of U.S. Pat. No. 5,288,677.

It is preferred that the support material, most preferably an inorganic oxide, has a surface area in the range of from about 10 to about 700 m²/g, pore volume in the range of from about 0.1 to about 4.0 cc/g and average particle size in the range of from about 5 to about 500 μm. More preferably, the surface area of the support material is in the range of from about 50 to about 500 m²/g, pore volume of from about 0.5 to about 3.5 cc/g and average particle size of from about 10 to about 200 μm. The average pore size of the carrier is typically in the range of from 10 to 1000 angstroms, preferably 50 to about 500 angstroms, and most preferably 75 to about 350 angstroms.

The support materials may be treated chemically, for example with a fluoride compound as described in WO 00/12565. Other supported activators are described in for example WO 00/13792 that refers to supported boron containing solid acid complex.

In one embodiment, the support material having an alumoxane compound bonded thereto may be prepared by combining the aluminum containing compound with the support material in a suitable solvent. In one embodiment, the combining is carried out at any suitable pressure and temperature under an inert atmosphere. Preferably the combining is at atmospheric pressure, ambient temperature under nitrogen. More preferably the mixture is heated to less than about 200° C., more preferably less than 150° C. The reactants are contacted for a suitable about of time for example, for at least about 1 minute, preferably about 1 minute to about 10 hours, more preferably for about 1 minute to about 3 hours.

In another embodiment, an antistatic agent or surface modifier that is used in the preparation of the supported catalyst system as described in PCT publication WO 96/11960 may be used with catalyst systems including the activator compounds described herein. The catalyst systems may also be prepared in the presence of an olefin, for example 1-hexene.

In another embodiment, the activator and/or catalyst system may be combined with a carboxylic acid salt of a metal ester, for example aluminum carboxylates such as aluminum mono, di- and tri-stearates, aluminum octoates, oleates and cyclohexylbutyrates, as described in U.S. Pat. Nos. 6,300,436 and 6,306,984.

In another embodiment there is a method for producing a supported metallocene-type catalyst system, which may be used to support the activator described herein. In this method, the catalyst compound is slurried in a liquid to form a catalyst solution or emulsion. A separate solution is formed containing the activator. The liquid may be any compatible solvent or other liquid capable of forming a solution or the like with the catalyst compounds and/or activator. In the most preferred embodiment the liquid is a cyclic aliphatic or aromatic hydrocarbon, most preferably toluene. The catalyst compound and activator solutions are mixed together heated and added to a heated porous support or a heated porous support is added to the solutions such that the total volume of the metallocene-type catalyst compound solution and the activator solution or the metallocene-type catalyst compound and activator solution is less than four times the pore volume of the porous support, more preferably less than three times, even more preferably less than two times; preferred ranges being from 1.1 times to 3.5 times range and most preferably in the 1.2 to 3 times range.

In one embodiment, a method of forming a supported catalyst system, the amount of liquid, in which the activator described herein and/or a catalyst compound is present, is in an amount that is less than four times the pore volume of the support material, more preferably less than three times, even more preferably less than two times; preferred ranges being from 1.1 times to 3.5 times range and most preferably in the 1.2 to 3 times range. In an alternative embodiment, the amount of liquid in which the activator is present is from one to less than one times the pore volume of the support material utilized in forming the supported activator.

In one embodiment, the amount of heterocyclic heteroatom containing compound ranges from 0.005 grams to 2.0 grams per gram of alumoxane treated silica. In another embodiment, the amount of heterocyclic heteroatom containing compound ranges from 0.05 grams to 1.0 grams per gram of alumoxane treated silica. In yet another embodiment, the amount of heterocyclic containing compound ranges from 0.075 grams to 0.8 grams per gram of alumoxane treated silica.

Polymerization Process

The activators and catalysts described above, whether supported or not, are suitable for use in any prepolymerization and/or polymerization process over a wide range of temperatures and pressures. The temperatures may be in the range of from −60° C. to about 280° C., preferably from 50° C. to about 200° C. In one embodiment, the polymerization temperature is above 0° C., above 50° C., above 80° C., above 100° C., above 150° C., or above 200° C. In one embodiment, the pressures employed may be in the range from 1 atmosphere to about 500 atmospheres (approx 101 kPa to 50650 kPa) or higher.

Polymerization processes include solution, gas phase, slurry phase, and a high pressure process, or a combination thereof. Particularly preferred is a gas phase or slurry phase polymerization of one or more olefin(s) at least one of which is ethylene or propylene.

In one embodiment, the process is a solution, high pressure, slurry or gas phase polymerization process of one or more olefin monomers having from 2 to 30 carbon atoms, preferably 2 to 12 carbon atoms, and more preferably 2 to 8 carbon atoms. The invention is particularly well suited to the polymerization of two or more olefin monomers of ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene and 1-decene.

Other monomers useful in the process include ethylenically unsaturated monomers, diolefins having 4 to 18 carbon atoms, conjugated or nonconjugated dienes, polyenes, vinyl monomers and cyclic olefins. Non-limiting monomers useful in the invention may include norbornene, norbornadiene, isobutylene, isoprene, vinylbenzocyclobutane, styrenes, alkyl substituted styrene, ethylidene norbornene, dicyclopentadiene and cyclopentene.

In another embodiment, a copolymer of ethylene is produced, where with ethylene, a comonomer having at least one alpha-olefin having from 4 to 15 carbon atoms, preferably from 4 to 12 carbon atoms, and most preferably from 4 to 8 carbon atoms, is polymerized in a gas phase process.

In another embodiment, ethylene or propylene is polymerized with at least two different comonomers, optionally one of which may be a diene, to form a terpolymer.

In one embodiment, the invention is directed to a polymerization process, particularly a gas phase or slurry phase process, for polymerizing propylene alone or with one or more other monomers including ethylene, and/or other olefins having from 4 to 12 carbon atoms.

Typically in a gas phase polymerization process, a continuous cycle is employed where in one part of the cycle of a reactor system, a cycling gas stream, otherwise known as a recycle stream or fluidizing medium, is heated in the reactor by the heat of polymerization. This heat is removed from the recycle composition in another part of the cycle by a cooling system external to the reactor. Generally, in a gas fluidized bed process for producing polymers, a gaseous stream containing one or more monomers is continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions. The gaseous stream is withdrawn from the fluidized bed and recycled back into the reactor. Simultaneously, polymer product is withdrawn from the reactor and fresh monomer is added to replace the polymerized monomer.

The reactor pressure in a gas phase process may vary from about 100 psig (690 kPa) to about 500 psig (3448 kPa), preferably in the range of from about 200 psig (1379 kPa) to about 400 psig (2759 kPa), more preferably in the range of from about 250 psig (1724 kPa) to about 350 psig (2414 kPa).

The reactor temperature in a gas phase process may vary from about 30° C. to about 120° C., preferably from about 60° C. to about 115° C., more preferably in the range of from about 70° C. to 110° C., and most preferably in the range of from about 70° C. to about 95° C. In another embodiment, the reactor temperature in a gas phase process is above 60° C.

Other gas phase processes include series or multistage polymerization processes. Also gas phase processes contemplated by the invention include those described in U.S. Pat. Nos. 5,627,242, 5,665,818 and 5,677,375, and European publications EP-A-0 794 200 EP-B1-0 649 992, EP-A-0 802 202 and EP-B-634 421.

In another embodiment, the process may produce greater than 500 lbs of polymer per hour (227 Kg/hr) to about 200,000 lbs/hr (90,900 Kg/hr) or higher of polymer, preferably greater than 1000 lbs/hr (455 Kg/hr), more preferably greater than 10,000 lbs/hr (4540 Kg/hr), even more preferably greater than 25,000 lbs/hr (11,300 Kg/hr), still more preferably greater than 35,000 lbs/hr (15,900 Kg/hr), still even more preferably greater than 50,000 lbs/hr (22,700 Kg/hr) and most preferably greater than 65,000 lbs/hr (29,000 Kg/hr) to greater than 100,000 lbs/hr (45,500 Kg/hr).

A slurry polymerization process generally uses pressures in the range of from about 1 to about 50 atmospheres (5065 kPa) and even greater and temperatures in the range of 0° C. to about 120° C. In another embodiment, the slurry process temperature is above 100° C. In a slurry polymerization, a suspension of solid, particulate polymer is formed in a liquid polymerization diluent medium to which ethylene and comonomers and often hydrogen along with catalyst are added. The suspension including diluent is intermittently or continuously removed from the reactor where the volatile components are separated from the polymer and recycled, optionally after a distillation, to the reactor. The liquid diluent employed in the polymerization medium is typically an alkane having from 3 to 7 carbon atoms, preferably a branched alkane. The medium employed should be liquid under the conditions of polymerization and relatively inert. When a propane medium is used the process must be operated above the reaction diluent critical temperature and pressure. Preferably, a hexane or an isobutane medium is employed.

In another embodiment, the polymerization technique is referred to as a particle form polymerization, or a slurry process where the temperature is kept below the temperature at which the polymer goes into solution. Such technique is well known in the art, and described in for instance U.S. Pat. No. 3,248,179 which is fully incorporated herein by reference. Other slurry processes include those employing a loop reactor and those utilizing a plurality of stirred reactors in series, parallel, or combinations thereof. Non-limiting examples of slurry processes include continuous loop or stirred tank processes. Also, other examples of slurry processes are described in U.S. Pat. No. 4,613,484, which is herein fully incorporated by reference.

In another embodiment, the process may produce greater than 2000 lbs of polymer per hour (907 Kg/hr), more preferably greater than 5000 lbs/hr (2268 Kg/hr), and most preferably greater than 10,000 lbs/hr (4540 Kg/hr). In another embodiment the slurry reactor may produce greater than 15,000 lbs of polymer per hour (6804 Kg/hr), preferably greater than 25,000 lbs/hr (11,340 Kg/hr) to about 100,000 lbs/hr (45,500 Kg/hr).

Examples of solution processes are described in U.S. Pat. Nos. 4,271,060, 5,001,205, 5,236,998 and 5,589,555 and PCT WO 99/32525.

In one embodiment the slurry or gas phase process is operated in the presence of the catalyst system described herein and in the absence of or essentially free of any scavengers, such as triethylaluminum, trimethylaluminum, tri-isobutylaluminum and tri-n-hexylaluminum and diethyl aluminum chloride, dibutyl zinc and the like. This process is described in PCT publication WO 96/08520 and U.S. Pat. Nos. 5,712,352 and 5,763,543.

In another embodiment, the catalyst system may be injected into a reactor, particularly a gas phase reactor. In one embodiment the catalyst system is used in the unsupported form, preferably in a liquid form such as described in U.S. Pat. Nos. 5,317,036 and 5,693,727 and European publication EP-A-0 593 083. The polymerization catalyst in liquid form can be fed with an activator, and/or a support, and/or a supported activator together or separately to a reactor. The injection methods described in PCT publication WO 97/46599 may be utilized.

Where an unsupported catalyst system is used the mole ratio of the metal of the activator component to the metal of the catalyst compound is in the range of between 0.3:1 to 10,000:1, preferably 100:1 to 5000:1, and most preferably 500:1 to 2000:1.

Polymer Products

The polymers produced can be used in a wide variety of products and end-use applications. The polymers produced include linear low density polyethylene, elastomers, plastomers, high density polyethylenes, medium density polyethylenes, low density polyethylenes, polypropylene and polypropylene copolymers.

The polymers, typically ethylene based polymers, have a density in the range of from 0.86 g/cc to 0.97 g/cc, preferably in the range of from 0.88 g/cc to 0.965 g/cc, more preferably in the range of from 0.900 g/cc to 0.96 g/cc, even more preferably in the range of from 0.905 g/cc to 0.95 g/cc, yet even more preferably in the range from 0.910 g/cc to 0.940 g/cc, and most preferably greater than 0.915 g/cc, preferably greater than 0.920 g/cc, and most preferably greater than 0.925 g/cc. Density is measured in accordance with ASTM-D-1238.

The polymers produced typically have a molecular weight distribution, a weight average molecular weight to number average molecular weight (M_(w)/M_(n)) of greater than 1.5 to about 15, particularly greater than 2 to about 10, more preferably greater than about 2.2 to less than about 8, and most preferably from 2.5 to 8. The polymers may have a narrow molecular weight distribution and a broad composition distribution or vice-versa, and may be those polymers described in U.S. Pat. No. 5,798,427.

Also, the polymers typically have a narrow composition distribution as measured by Composition Distribution Breadth Index (CDBI). Further details of determining the CDBI of a copolymer are known to those skilled in the art. See, for example, PCT Patent Application WO 93/03093, published Feb. 18, 1993. The polymers in one embodiment have CDBI's generally in the range of greater than 50% to 100%, preferably 99%, preferably in the range of 55% to 85%, and more preferably 60% to 80%, even more preferably greater than 60%, still even more preferably greater than 65%. In another embodiment, polymers produced using a catalyst system described herein have a CDBI less than 50%, more preferably less than 40%, and most preferably less than 30%.

The polymers in one embodiment have a melt index (MI) or (12) as measured by ASTM-D-1238-E (190/2.16) in the range from no measurable flow to 1000 dg/min, more preferably from about 0.01 dg/min to about 100 dg/min, even more preferably from about 0.1 dg/min to about 50 dg/min, and most preferably from about 0.1 dg/min to about 10 dg/min.

In one embodiment, the polymers have a melt index ratio (I₂1/I₂) (I₂₁ is measured by ASTM-D-1238-F) (190/21.6) of from 10 to less than 25, more preferably from about 15 to less than 25. The polymers, in a preferred embodiment, have a melt index ratio (I₂₁/I₂) of from greater than 25, more preferably greater than 30, even more preferably greater that 40, still even more preferably greater than 50 and most preferably greater than 65. For example, melt index ratio (I₂₁/I₂) may be of from 5 to 300, 10 to 200, 20 to 180, 30 to 160, 40 to 120, 50 to 100, 60 to 90, and a combination of any upper limit with any lower limit.

In yet another embodiment, propylene based polymers are produced. These polymers include atactic polypropylene, isotactic polypropylene, hemi-isotactic and syndiotactic polypropylene. Other propylene polymers include propylene block or impact copolymers. Propylene polymers of these types are well known in the art see for example U.S. Pat. Nos. 4,794,096, 3,248,455, 4,376,851, 5,036,034 and 5,459,117.

The polymers may be blended and/or coextruded with any other polymer. Non-limiting examples of other polymers include linear low density polyethylenes, elastomers, plastomers, high pressure low density polyethylene, high density polyethylenes, polypropylenes and the like.

The polymers produced and blends thereof are useful in such forming operations as film, sheet, and fiber extrusion and co-extrusion as well as blow molding, injection molding and rotary molding. Films include blown or cast films formed by coextrusion or by lamination useful as shrink film, cling film, stretch film, sealing films, oriented films, snack packaging, heavy duty bags, grocery sacks, baked and frozen food packaging, medical packaging, industrial liners, membranes, etc. in food-contact and non-food contact applications. Fibers include melt spinning, solution spinning and melt blown fiber operations for use in woven or non-woven form to make filters, diaper fabrics, medical garments, geotextiles, etc. Extruded articles include medical tubing, wire and cable coatings, pipe, geomembranes, and pond liners. Molded articles include single and multi-layered constructions in the form of bottles, tanks, large hollow articles, rigid food containers and toys, etc.

The following paragraphs enumerated consecutively from 1 through 12 provide for various aspects of the present invention. This invention further relates to:

1. A catalyst system comprising: a metallocene; an activator comprising one or more heterocyclic heteroatom containing ligands coordinated to an alkyl alumoxane, wherein the activator is a reaction product of one or more alkyl alumoxane and one or more heterocyclic heteroatom containing compounds, wherein the heterocyclic heteroatom containing ligand is represented by:

Y is O, S, PH or NH;

wherein each substituent X2, X3, X4, X5, X6 and X7 is independently a hydrogen, chlorine, fluorine, iodine or bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH; and wherein the ratio of the heterocyclic heteroatom containing ligand to aluminum is between about 0.01 and about 10 molar equivalents. 2. The catalyst of paragraph 1, wherein the metallocene is rac-Me₂Si-(2-methyl-indenyl)₂Zr(CH₃)₂ or rac-Me₂Si-(2-methyl-4-phenyl-indenyl)₂Zr(CH₃)₂. 3. The catalyst of either of paragraphs 1 or 2, wherein the heterocyclic heteroatom containing ligand is mono-substituted. 4. The catalyst of paragraph 3, wherein the substituent is a bromine. 5. The catalyst of either of paragraphs 1 or 2, wherein the heterocyclic heteroatom containing ligand is di-substituted. 6. The catalyst of paragraph 5, wherein the substituents are chlorines. 7. The catalyst of any of paragraphs 1 through 6, wherein the ratio of heterocyclic heteroatom containing ligand to aluminum is between about 0.2 and about 5. 8. The catalyst of any of paragraphs 1 through 7, wherein Y is NH. 9. A process to polymerize one or more olefins comprising the step of contacting one or more olefins with a catalyst system of any of paragraphs 1 through 8. 10. The process of paragraph 9, wherein the one olefin is propylene. 11. The process of paragraph 10, wherein the molecular weight of the polymerized propylene is between about 5,000 and about 200,000. 12. The process of paragraph 11, wherein the molecular weight of the polymerized propylene is between about 10,000 and 15,000.

EXAMPLES

Isobutylalumoxane was obtained commercially from Akzo Nobel Chemicals Inc. in two formulations: isobutylalumoxane (0.65H2O/Al), 3.5 wt % Al in hexanes and isobutylalumoxane (0.80H₂O/Al), 3.5 wt % Al in heptane. The solvents used in both these formulations proved unsuitable for downstream reactions so, the solvents were replaced with the more polar solvent, toluene.

1. Synthesis of IBAO solutions: Replacement of solvent

Isobutylalumoxane (0.65H₂O/Al):

Isobutylalumoxane (0.65H₂O/Al), 3.5 wt % Al in hexanes was dried under vacuum to remove the hexanes and thereby yielded a viscous slurry. The slurry was weighed and then re-dissolved in an appropriate amount of toluene to give a 2.6 wt % solution.

In another embodiment, the slurry was weighed and re-dissolved in an appropriate amount of toluene to give a 10 wt % solution. These isobutylalumoxane solutions, IBAO (0.65, 2.6 wt % in toluene) and IBAO (0.65, 10 wt % in toluene), were used to prepare a series of liquid catalysts by reaction with selected organic ligands as shown below.

Isobutylalumoxane (0.80H₂O/Al):

Similarly, isobutylalumoxane (0.80H₂O/Al), 3.5 wt % Al in heptane was dried under vacuum to remove the heptane to yield a viscous slurry. The slurry was weighed and then re-dissolved in an appropriate amount of toluene to give a 10 wt % solution. This isobutylalumoxane solution, IBAO (0.80, 10 wt % in toluene), was used to prepare a series of liquid catalysts by reaction with selected organic ligands as shown below.

2. Reactions with IBAO (0.65):

Representative indoles were reacted with these IBAO solutions. The ratio of heterocycle to aluminum was shown to influence both the activity of the catalyst and the molecular weight of the resulting isotactic polypropylene.

I. Indole:

Synthesis of IBAO (0.65, 10 wt % in toluene)-INDO

10.4 g IBAO (0.65, 10 wt % in toluene) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 5.0 g of indole was added to the solution. The indole dissolved readily to yield a yellow-orange solution. The solution was stirred overnight. The solution appeared to be fairly stable as no precipitation was observed even after storage at room temperature for a few months. [IBAO (0.65, 10 wt % in toluene)-5.0-INDO (24848-52)]

II. Halogenated Indoles: 5-Bromoindole:

Synthesis of IBAO (0.65, 2.6 wt % in toluene)-5-BrINDO

40 g IBAO (0.65, 2.6 wt % in toluene) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 0.25 g of 5-bromoindole (Biosynth International) was added to the solution. The 5-bromoindole dissolved readily to yield a very pale yellow solution. The solution was stirred overnight. [IBAO (0.65, 2.6 wt % in toluene)-0.25-5-BrINDO (24848-36)].

This reaction was conducted in various iterations by changing the amount of 5-bromoindole added. Solutions were made with 0.5 g [IBAO (0.65, 2.6 wt % in toluene)-0.5-5-BrINDO (24848-37)], 1.0 g [IBAO (0.65, 2.6 wt % in toluene)-1,0-5-BrINDO (24848-37)], and 5.0 g [IBAO (0.65, 2.6 wt % in toluene)-5,0-5-BrINDO (24848-39)]. All solutions appeared to be fairly stable since no precipitation was observed even after storage at room temperature for a few months.

5,6-Dichloroindole:

Synthesis of IBAO (0.65, 10 wt % in toluene)-2,3-C₁₂INDO

40 g IBAO (0.65, 10 wt % in toluene) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 2.0 g of 5,6-dichloroindole (Biosynth International) was added to the solution. The 5,6-dichloroindole dissolved readily to yield a yellow-orange solution. The solution was stirred overnight. The solution appeared to be fairly stable since no precipitation was observed even after storage at room temperature for a few months. [IBAO (0.65, 10 wt % in toluene)-0.5-2,3-Cl₂INDO (24848-79)]

3. Reactions with IBAO (0.80):

Representative members of the indole groups of organic ligands were reacted with these IBAO solutions. Reactivity of the individual ligands with the IBAO solutions varied depending on the substitutions on the ligand backbone. The effect of placing halogens or sterically bulky organic substituents on the ligand backbone on the resultant polypropylene polymer was investigated.

I. Halogenated Indoles: 5-Bromoindole:

Synthesis of IBAO (0.80, 10 wt % in toluene)-5-BrINDO

10.4 g IBAO (0.80, 10 wt % in toluene) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 0.25 g of 5-bromoindole (Biosynth International) was added to the solution. The 5-bromoindole dissolved readily to yield a yellow solution. The solution was stirred overnight. [IBAO (0.80, 10 wt % in toluene)-0.25-5-BrINDO (24848-121)].

This reaction was conducted in various iterations by changing the amount of 5-bromoindole added. Solutions were made with 0.5 g [IBAO (0.80, 10 wt % in toluene)-0.5-5-BrINDO (24848-122)], 0.75 g [IBAO (0.80, 10 wt % in toluene)-0.75-5-BrINDO (24848-182)], 11.0 g [IBAO (0.80, 10 wt % in toluene)-1,0-5-BrINDO (24848-123)] and 5.0 g [IBAO (0.80, 10 wt % in toluene)-5,0-5-BrINDO (24848-124)]. All solutions appeared to be fairly stable since no precipitation was observed even after storage at room temperature for a few months.

5-Chloroindole:

Synthesis of IBAO (0.80, 10 wt % in toluene)-5-chloroindole

10.0 g IBAO (0.80, 10 wt % in toluene) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 0.19 g of 5-chloroindole (Biosynth International) was added to the solution. The 5-chloroindole dissolved readily to yield a yellow solution. The solution was stirred overnight. [IBAO (0.80, 10 wt % in toluene)-0.19-5-ClINDO (24848-168)].

This reaction was conducted in various iterations by changing the amount of 5-chloroindole added. Solutions were made with 0.4 g [IBAO (0.80, 10 wt % in toluene)-0.40-5-ClINDO (24848-184)] and 0.65 g [IBAO (0.80, 10 wt % in toluene)-0.65-5-ClINDO (24848-127)].

All the solutions appeared to be fairly stable as no precipitation was observed even after storage at room temperature for a few days.

II. Substituted Indoles 2-Phenylindole:

Synthesis of IBAO (0.80, 10 wt %)-2-phenylindole

20.0 g IBAO (0.80, 10 wt %) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 1.96 g of 2-phenylindole was added to the solution. The 2-phenylindole dissolved readily to yield a yellow solution. The solution was stirred overnight. Yellow crystals were observed to fall out of solution on standing for a few days. [IBAO (0.80, 10 wt %)-0.83-2-phenylindole (24848-128)].

2,3-Dimethyl Indole:

Synthesis of IBAO (0.80, 10 wt %)-2,3-dimethylindole

10.4 g IBAO (0.80, 10 wt %) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 0.19 g of 2,3-dimethylindole was added to the solution. The 2,3-dimethylindole dissolved readily to yield a yellow solution. The solution was stirred overnight. The solution appeared to be fairly stable as no precipitation was observed even after storage at room temperature for a few days. [IBAO (0.80, 10 wt %)-0.19-2,3-dimethyl-indole (24848-176)]. This reaction was conducted in various iterations by changing the amount of 2,3-dimethylindole added: 0.38 grams and 0.76 grams [IBAO (0.80, 10 wt %)-0.38-2,3-dimethyl-indole (24848-)][IBAO (0.80, 10 wt %)-0.76-2,3-dimethyl-indole (24848-)]3-Methylindole:

Synthesis of IBAO (0.80, 10 wt %)-3-Methylindole

10.4 g IBAO (0.80, 10 wt %) solution was weighed into a dry Wheaton glass bottle. A stir bar was added. 0.17 g of 3-methylindole was added to the solution. The 3-methylindole dissolved readily to yield a yellow solution. The solution was stirred overnight. [IBAO (0.80, 10 wt %)-0.17-3-MeINDO (24848-177)].

This reaction was conducted in various iterations by changing the amount of 5-chloroindole added. Solutions were made of 0.34 g [IBAO (0.80, 10 wt %)-0.34-3-MeINDO (24848-185)], and 0.8 g [IBAO (0.80, 10 wt %)-0.80-3-MeINDO (24848-186)]. All solutions appeared to be fairly stable as no precipitation was observed even after storage at room temperature for a few days.

Experimental—Polymerizations: In the following slurry phase experiments pressure is reported in atmospheres and pounds per square inch. The conversion factors to S.I. Units are; 1 psi equals 6.894757 kPa and 1 atm equals 101.325 kPa.

Feed

Polymerization grade propylene was used and further purified by passing it through a series of columns: 500 cc Oxyclear cylinder from Labelear (Oakland, Calif.) followed by a 500 cc column packed with dried 3 Å mole sieves purchased from Aldrich Chemical Company, and a 500 cc column packed with dried 5 Å mole sieves purchased from Aldrich Chemical Company.

Scavengers/Co-catalysts

Triisobutyl aluminum (TIBAL) was obtained from Akzo Chemicals, Inc. and used without further purification. Tri n-octyl aluminum (TNOAL) was obtained from Akzo Chemicals, Inc. and used without further purification.

Polymerization grade hexane was used and further purified by passing it through a series of columns: 500 cc Oxyclear cylinder from Labelear (Oakland, Calif.) followed by a 500 cc column packed with dried 3 Å mole sieves purchased from Aldrich Chemical Company, and a 500 cc column packed with dried 5 Å mole sieves purchased from Aldrich Chemical Company.

Reactor Description and Preparation

Polymerizations were conducted in an inert atmosphere (N₂) drybox using autoclaves equipped with an external heater for temperature control, glass inserts (internal volume of reactor=22.5 mL), septum inlets, regulated supply of nitrogen, propylene, and equipped with disposable PEEK mechanical stirrers (400 RPM). The autoclaves were prepared by purging with dry nitrogen at 110° C. or 115° C. for 5 hours and then at 25° C. for 5 hours.

Propylene Polymerization:

The reactor was prepared as described above, and then purged with propylene. The reactors were heated to 40° C. and propylene was first charged to the reactor.

A solution of scavenger/co-catalyst at room temperature and pressure was next added to the reactors via syringe. The reactors were then brought to process temperature (70° C.) while stirring at 400 RPM.

In the nature that solutions are added via syringe, a hexanes solution is also injected via the same syringe following their addition to insure that minimal solution is remaining in the syringe. This procedure is applied after the addition of the scavenger/co-catalyst solution as well as the catalyst slurry.

Propylene was allowed to enter (through the use of computer controlled solenoid valves) the autoclaves during polymerization to maintain reactor gauge pressure 450 psi(+/−2 psig). Reactor temperature was monitored and typically maintained within +/−1° C. Polymerizations were halted by addition of approximately 400 psig O₂/Ar (5 mole % O₂) gas mixture to the autoclaves for approximately 30 seconds. The polymerizations were quenched after 45 minutes polymerization time. The reactors were cooled and vented. The polymer was isolated after the remaining reaction components were removed in-vacuo.

Polymer Characterization:

Polymer characterization results for polypropylene samples are reported in table 1. For analytical testing, polymer sample solutions were prepared by dissolving polymer in 1,2,4-trichlorobenzene (TCB, 99+% purity from Sigma-Aldrich) containing 2,6-di-tert-butyl-4-methylphenol (BHT, 99% from Aldrich) at 145° C. in a shaker oven for approximately 3 hours. The typical final concentration of polymer in solution is between 0.4 to 0.9 mg/mL with a BHT concentration of 1.25 mg BHT/mL of TCB. Samples are cooled to 135° C. for testing

Molecular weights (weight average molecular weight (Mw) and number average molecular weight (Mn)) and molecular weight distribution (MWD=Mw/Mn), which is also sometimes referred to as the polydispersity (PDI) of the polymer, were measured by Gel Permeation Chromatography using a Symyx Technology GPC equipped with evaporative light scattering detector and calibrated using polystyrene standards from Polymer Mp (peak Mw) between 5000 and 3,390,000). Samples were run in TCB at (135° C. sample temperatures, 165° C. oven/columns) using three Polymer Laboratories: PLgel 10 m Mixed-B 300×7.5 mm columns in series. No column spreading corrections were employed. Numerical analyses were performed using Epochg software available from Symyx Technologies.

Samples for DSC were performed on a TA Instruments Q100 DSC.

Sample preparation. To prepare the samples, approximately 0.07 g of each polymer were weighed into tared glass vials. Each glass vial was then weighed by the Bohdan weigh station, and 2.8 ml of trichlorobenzene with BHT was added to each vial using the Rapid GPC prep station to obtain 25 mg/ml solutions. The polymers were then dissolved at 165° C. with mixing bars and agitation. The Rapid GPC station then automatically dispensed approximately 0.4 ml of each polymer solution into DSC pans. The trichlorobenzene was evaporated at 165° C. over approximately 15 minutes.

The DSC pans were then annealed in an oven purged with nitrogen to give them the same thermal history. The samples were annealed at 220° C. for 15 minutes, and allowed to cool overnight to room temperature.

DSC measurements. The following heating and cooling sequence were used to test samples in a high throughput mode. The first melt occurs when the pans are annealed in parallel in the purged oven.

1) Ramp 100° C./min to 220° C. (second melt)

2) Hold 1 min at 220° C.

3) Ramp 50° C./min to 40° C. (crystallization)

TABLE 1 Catalyst: rac-Me₂Si(2-methyl-indenyl)₂Zr(CH₃)₂/IBAO(0.65)(5-BrINDO) Activity Average Average Average actual Yield (gPP/m Activator Mn Mw PDI quench time (grams) moleZrsec) MAO(comparative) 59958 86,497 1.44 340 0.0771 1.51 57377 82,644 1.44 264 0.0565 1.42 66141 95,024 1.43 379 0.0835 1.47 68804 99,261 1.44 349 0.0849 1.62 65679 94,400 1.43 376 0.086 1.52 65497 94,212 1.43 363 0.0826 1.52 IBAO(0.65) 900 0.0082 0.0607 (comparative) 900 0.0063 0.0466 900 0.0045 0.0333 901 0.0061 0.0451 900 0.0049 0.0363 900 0.0054 0.04 IBAO(0.65)-0.5-5,6- 9143 13,878 1.51 123 0.1322 7.14 dichloroindolyl- 9737 14,683 1.50 131 0.1228 6.23 9724 14,654 1.50 111 0.1035 6.21 9281 14,077 1.51 138 0.1486 7.16 10034 15,301 1.52 122 0.1233 6.73 8977 13,596 1.51 148 0.1521 6.84 IBAO(0.65)-0.25-5- 119434 175,855 1.47 900 0.0327 0.242 BrINDO 119839 175,225 1.46 900 0.0299 0.221 132647 193,977 1.46 901 0.033 0.244 128962 188,859 1.46 900 0.0324 0.24 131956 189,494 1.43 900 0.0311 0.23 127470 185,011 1.45 659 0.0287 0.29 IBAO(0.65)-0.5-5- 53418 79,319 1.48 900 0.045 0.333 BrINDO 64681 93,723 1.44 900 0.0456 0.338 63139 91,912 1.45 900 0.054 0.4 61018 88,779 1.45 900 0.049 0.363 59733 86,593 1.44 900 0.0481 0.356 62484 90,644 1.45 900 0.0484 0.358 IBAO(0.65)-1.0-5- 39682 58,704 1.47 665 0.0623 0.624 BrINDO 38694 57,356 1.48 548 0.0607 0.738 44832 66,142 1.47 630 0.0732 0.774 38621 56,370 1.45 614 0.0668 0.725 39743 58,470 1.47 758 0.0555 0.488 38227 56301 1.47 616 0.0605 0.654 IBAO(0.65)-5.0-5- 7587 11755 1.54 92.9 0.1209 8.676 BrINDO 7295 11286 1.54 94.2 0.1265 8.953 4598 6843 1.48 186 0.0816 2.911 7782 12196 1.56 104 0.136 8.651 7600 11957 1.57 102 0.1312 8.575 7933 12512 1.57 106 0.1337 8.393 30 umoles activator, 0.15 umoles catalyst

TABLE 2 Catalyst: rac-Me₂Si(2-methyl-indenyl)₂Zr(CH₃)₂/IBAO(0.80)(5-BrINDO) actual Average Average quench Yield Activator Average Mn Mw PDI time (grams) Activity Tm MAO(comparative) 64342 95,120 1.48 196 0.1134 3.85 139 60805 87,069 1.43 183 0.0998 3.64 58688 84,690 1.44 163 0.0886 3.62 138 IBAO(0.80)-0.25-5- 11363 18,765 1.65 351 0.0813 1.55 143 BrINDO 10425 18,387 1.76 400 0.0826 1.38 141 10829 18,500 1.71 438 0.0841 1.28 IBAO(0.80)-0.5-5- 7674.6 11,722 1.53 155 0.0603 2.59 BrINDO 8481.7 12,226 1.44 192 0.0747 2.59 145 7867.5 11,959 1.52 209 0.0616 1.96 8291.6 12,483 1.51 193 0.0717 2.47 144 8305.6 12,384 1.49 204 0.0613 2 8094.3 11,949 1.48 225 0.0526 1.56 145 IBAO(0.80)-1.0-5- 10910 16,689 1.53 901 0.0118 0.087 BrINDO 12042 17,378 1.44 900 0.0117 0.087 11483 16,768 1.46 900 0.0113 0.084 11522 17,390 1.51 901 0.0128 0.095 900 0.0031 0.023 901 0.0091 0.067 IBAO(0.80)-5.0-5- 647 0.0111 0.114 BrINDO 901 0.0109 0.081 900 0.011 0.081 901 0.0114 0.084 901 0.0116 0.086 901 0.0114 0.084 30 umoles activator, 0.15 umoles catalyst

TABLE 3 Catalyst: rac-Me₂Si(2-methyl4-phenyl-indenyl)₂Zr(CH₃)₂/IBAO(0.80)(5-BrINDO) actual Average Average Average quench Yield Activator Mn Mw PDI time (grams) Activity Tm IBAO(0.80)-0.25-5- 66724 101,616 1.52 350 0.0517 0.985 158 BrINDO 64749 102,254 1.58 438 0.1216 1.853 160 65609 102,692 1.57 424 0.1174 1.846 159 63056 98,622 1.56 348 0.126 2.415 159 65205 98,728 1.51 390 0.0847 1.449 159 60785 95,012 1.56 385 0.1001 1.733 159 IBAO(0.80)-0.5-5- 35989 53,111 1.48 142 0.0992 4.654 157 BrINDO 42897 62,850 1.47 160 0.0939 3.903 157 42867 62,792 1.46 156 0.0822 3.522 158 40746 59,229 1.45 145 0.1012 4.663 157 39510 58,674 1.49 144 0.0877 4.057 156 37159 56,596 1.52 150 0.0603 2.684 157 IBAO(0.80)-1.0-5- 48756 69,713 1.43 109 0.0259 1.587 BrINDO 53216 79,628 1.5 92 0.0284 2.058 158 58011 81,221 1.4 94.8 0.0265 1.864 157 55280 80,676 1.46 85.8 0.0287 2.23 157 53123 77,432 1.46 80.7 0.0311 2.569 156 53174 76,605 1.44 112 0.0173 1.033 135 IBAO(0.80)-5.0-5- 901 0.0113 0.084 BrINDO 901 0.0113 0.084 900 0.0115 0.085 900 0.0122 0.09 901 0.0124 0.092 900 0.0123 0.091 30 umoles activator, 0.15 umoles catalyst

All documents described herein are incorporated by reference herein, including any priority documents and/or testing procedures to the extent they are not inconsistent with this text. As is apparent from the foregoing general description and the specific embodiments, while forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited thereby. Likewise, the term “comprising” is considered synonymous with the term “including” for purposes of Australian law. 

1. A catalyst system comprising: a catalyst compound; an activator comprising one or more heterocyclic heteroatom containing ligands coordinated to an alkyl alumoxane, wherein the activator is a reaction product of one or more alkyl alumoxane and one or more heterocyclic heteroatom containing compounds, wherein the heterocyclic heteroatom containing ligand is represented by:

Y is O, S, PH or NH; wherein each substituent X2, X3, X4, X5, X6 and X7 is independently a hydrogen, chlorine, fluorine, iodine or bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH; and wherein the ratio of the heterocyclic heteroatom containing ligand to aluminum is between about 0.01 and about 10 molar equivalents.
 2. The catalyst system of claim 1 wherein the catalyst compound is a metallocene.
 3. The catalyst system of claim 2, wherein the metallocene is rac-Me₂Si-(2-methyl-indenyl)₂Zr(CH₃)₂ or rac-Me₂Si-(2-methyl-4-phenyl-indenyl)₂Zr(CH₃)₂.
 4. The catalyst system of claim 1, wherein the heterocyclic heteroatom containing ligand is mono-substituted.
 5. The catalyst system of claim 4, wherein the substituent is a bromine.
 6. The catalyst system of claim 1, wherein the heterocyclic heteroatom containing ligand is di-substituted.
 7. The catalyst system of claim 6, wherein the substituents are chlorines.
 8. The catalyst system of claim 1, wherein the ratio of heterocyclic heteroatom containing ligand to aluminum is between about 0.2 and about
 5. 9. The catalyst system of claim 1, wherein Y is NH.
 10. A process to polymerize one or more olefins comprising the step of contacting one or more olefins with a catalyst system comprising: a catalyst compound; an activator comprising one or more heterocyclic heteroatom containing ligands coordinated to an alkyl alumoxane, wherein the activator is a reaction product of one or more alkyl alumoxane and one or more heterocyclic heteroatom containing compounds, wherein the heterocyclic heteroatom containing ligand is represented by:

Y is O, S, PH or NH; wherein each substituent X2, X3, X4, X5, X6 and X7 is independently a hydrogen, chlorine, fluorine, iodine or bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH; and wherein the ratio of the heterocyclic heteroatom containing ligand to aluminum is between about 0.01 and about 10 molar equivalents.
 11. The process of claim 10 wherein the catalyst compound is a metallocene.
 12. The process of claim 10 wherein the heterocyclic heteroatom containing ligand is indole, bromoindole and/or dichloroindole.
 13. The process of claim 11, wherein the metallocene is rac-Me₂Si-(2-methyl-indenyl)₂Zr(CH₃)₂ or rac-Me₂Si-(2-methyl-4-phenyl-indenyl)₂Zr(CH₃)₂.
 14. The process of claim 10, wherein the heterocyclic heteroatom containing ligand is mono-substituted.
 15. The process of claim 14, wherein the substituent is a bromine.
 16. The process of claim 10, wherein the heterocyclic heteroatom containing ligand is di-substituted.
 17. The process of claim 16, wherein the substituents are chlorines.
 18. The process of claim 10, wherein the ratio of heterocyclic heteroatom containing ligand to aluminum is between about 0.2 and about
 5. 19. The process of claim 10, wherein Y is NH.
 20. The process of claim 10, wherein the olefin is propylene.
 21. The process of claim 10, wherein the molecular weight of the polymerized propylene is between about 5,000 and about 200,000.
 22. The process of claim 11, wherein the molecular weight of the polymerized propylene is between about 10,000 and 15,000.
 23. The process of claim 10 wherein the alumoxane is triisobutyl alumoxane, methylalumoxane, ethylalumoxane or a mixture thereof.
 24. An activator comprising one or more heterocyclic heteroatom containing ligands coordinated to an alkyl alumoxane, wherein the activator is a reaction product of one or more alkyl alumoxane and one or more heterocyclic heteroatom containing compounds, wherein the heterocyclic heteroatom containing ligand is represented by:

Y is O, S, PH or NH; wherein each substituent X2, X3, X4, X5, X6 and X7 is independently a hydrogen, chlorine, fluorine, iodine or bromine, provided at least one of X2, X3, X4, X5, X6 and X7 is not hydrogen when Y is NH; and wherein the ratio of the heterocyclic heteroatom containing ligand to aluminum is between about 0.01 and about 10 molar equivalents. 